Keston 30C Manual

Installation and Servicing Instructions

FAN POWERED HIGH EFFICIENCYMODULATING DOMESTIC CONDENSING

GAS COMBINATION BOILER

CE/PI No. 86-CL-38GC No. 47-930-03

30C

The Keston 30C

These instructions must be left either with the user or next to the site gas meter.

34 West Common RoadHayes, Bromley, Kent, BR2 7BX

Tel. +44 (0) 20 8462 0262 Fax. +44 (0) 20 8462 4459email : [email protected] web : www.keston.co.uk

COMPLIANT WITH BUILDING REGULATION PART L1 & L2

SEDBUK A RATED

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2 Keston 30C - Installation and Servicing

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3Keston 30C - Installation and Servicing

Relevant Installation changes implemented in this book from Mod Level ............................... A03 (June 2010)

DOCUMENT AMENDMENTS

Keston reserve the right to vary specification without notice

FOR ANY TECHNICAL QUERIES PLESE RING THE KESTONINSTALLER/TECHNICAL HELPLINE : 0208 462 0262

NOTE. BOILER RESET PROCEDURE -To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting.The boiler will repeat the ignition sequence.

NOTES FOR THE INSTALLER

Page 17 - Frame 9, Flue System• Approved Solvent Weld Waste added

Pae 37 - Frame 38, Wiring Diagram• Wire removed from flame sensor electrode

Page 73 - Short List of Parts• Key No. 111 - part number updated

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GENERAL

Keston 30C 30

Gas supply 2H - G20 - 20mbar

Gas Supply Connection 15mm copper compression

Injector Size (mm) 4.65

Inlet Connection Domestic Hot Water 15mm copper compression

Outlet Connection Domestic Hot Water 15mm copper compression

Flow Connection Central Heating 22mm copper compression

Return Connection Central Heating 22mm copper compression

Flue Terminal Diameter mm (in) 50 (nominal)

Average Flue Temp-Mass Flow Rate (DHW) 68oC - 13g/s

Maximum Working Pressure (Sealed Systems) bar (lb/in2) 2.5 (36.3)

Maximum Domestic Hot Water Inlet Pressure bar (lb/in2) 10.0 (145)

Minimum Domestic Hot Water Inlet Pressure* bar (lb/in2) 1.3 (18.9)

Electrical Supply 230 V ~ 50 Hz.

Power Consumption W 152

Fuse Rating External : 3A Internal : T4H HRC L250 V

Water content Central Heating litre (gal) 1.2 (0.26)Domestic Hot Water litre (gal) 0.5 (0.11)

Packaged Weight kg (lb) 37.8 (83.3)

Maximum Installation Weight kg (lb) 32.8 (72.3)

Boiler Casing Size Height mm (in) 700 (27.5)

Width mm (in) 395 (15.5)

Depth mm (in) 278 (11)

Table 1 - General Data

Note. Gas consumption is calculated using acalorific value of 38.7 MJ/m3 (1038 Btu/ft3) grossor 34.9 MJ/m3 (935 Btu/ft3) nett

To obtain the gas consumption at a differentcalorific value:

a. For l/s - divide the gross heat input (kW) bythe gross C.V. of the gas (MJ/m3)

b. For ft3/h - divide the gross heat input (Btu/h)by the gross C.V. of the gas (Btu/ft3)

c. For m3/h - multiply l/s by 3.6.

Key to symbols

PMS = Maximum operating pressure of water

C13 C33 C53 = A room sealed appliance designed for connection via ducts to ahorizontal or vertical terminal, which admits fresh air to the burnerand discharges the products of combustion to the outside throughorifices which, in this case, are concentric. The fan is up streamof the combustion chamber.

I2H = An appliance designed for use on 2nd Family gas, Group H only.

* The value is used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from whichit has been calculated have been certified by a notified body.

*Required for maximum flow rate. Boiler operates down to 2 l/min DHW delivery

Maximum DHW Input : 30

Nett CV kW 30.4

(Btu/h) (103,600)

Gross CV kW 33.7

(Btu/h) (115,000)

Gas Consumption l/s 0.871

(ft3/h) (111)

Maximum kW 30.3DHW Output (Btu/h) (103,300)

DHW Flow Rate l/min 12.4at 35°C temp. rise. (gpm) (2.8)

DHW Specific Rate l/min 14.5(gpm) (3.2)

Boiler Input : Max. Min.

Boiler Input ‘Q’ Nett CV kW 24.3 6.1

(Btu/h) (82,900) (20,700)

Gross CV kW 27.0 6.7

(Btu/h) (92,000) (23,000)

Gas Consumption l/s 0.698 0.173

(ft3/h) (89) (22)

Boiler Output :

Non Condensing kW 24.2 6.1

70oC Mean Water temp. (Btu/h) (82,600) (20,700)

Condensing kW 25.6 6.4

40oC Mean Water temp. (Btu/h) (87,400) (21,800)

Seasonal efficiency* (SEDBUK) Band A (91.1%)

NOx Classification CLASS 5

Table 2 - Performance Data - Central Heating Table 3 - Performance Data - Domestic Hot Water

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GENERAL

Boiler size G.C. Appliance No. PI No.(Benchmark No.)

30 47-930-03 86 CL 38

CONTENTS

Benchmark Commissioning Checklist ..................... 75

Boiler Clearances ......................................................... 9

Boiler Exploded Diagram ....................................... 13,14

Condensate Drain .............................................9, 20, 46

Electrical Connections ............................................... 31

Electrical Supply ........................................................... 8

Fault Finding ........................................................... 64-72

Flue Fitting .............................................................. 17, 18

Gas Safety Regulations ................................................ 7

Gas Supply ..................................................................... 8

Installation ............................................................. 15-43

Pump .......................................................................... 59

Safe Handling ................................................................ 6

Servicing ................................................................ 44-63

Short List of Parts ....................................................... 73

Thermostatic Radiator Valves ..................................... 8

Water and Systems .......................................... 8, 10-12

Water Connections ............................................... 28, 29

Water Treatment ......................................................... 12

Wiring Diagram ........................................................... 37

Natural Gas only

Boiler PageMake and model .......................................................5Appliance serial no. on data badge ....... Front CoverSEDBUK No. % .........................................................4

ControlsTime and temperature control to heating ............. 32Time and temperature control to hot water .......... 32Heating zone valves ..............................................n/aTRV's .........................................................................8Auto bypass ..............................................................8Boiler interlock ..........................................................8

For all boilersFlushing to BS.7593 .............................................. 12Inhibitor .................................................................. 12

Central heating modeHeat input ................................................ to be calculated

For assistance see Technical Helpline on the back page

PageBurner operating pressure ....................................n/aCentral heating flow temp. ...... measure and recordCentral heating return temp. ... measure and record

For combination boilers onlyScale reducer ......................................................... 12

Hot water modeHeat input .......................................... to be calculatedMax. operating burner pressure ..............................n/aMax. operating water pressure ........... measure & recordCold water inlet temp ..................... measure & recordHot water outlet temp. .................... measure & recordWater flow rate at max. setting ............ measure & record

For condensing boilers onlyCondensate drain .................................................. 26

For all boilers: complete, sign & hand over to customer

For GB, to comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be fitted in accordance with themanufacturer's instructions. Self-certification that the boiler has been installed to comply with Building Regulations can bedemonstrated by completing and signing the Benchmark Commissioning Checklist.

Before installing this boiler, read the Code of Practice sheet at the rear of this book.

BENCHMARK COMMISSIONING CHECKLIST DETAILS

NOTE TO THE INSTALLER: COMPLETETHE BENCHMARK COMMISSIONING

CHECKLIST AND LEAVE THESEINSTRUCTIONS WITH APPLIANCE

30C

KESTON 30C

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GENERAL

INTRODUCTIONThe Keston 30C boiler is a wall mounted, full sequence,automatic spark ignition, low water content, fanned flue, highefficiency, condensing, combination gas boiler.

Note. Due to the high efficiency of the boiler a plume of watervapour will form at the terminal during operation.

Central heating (CH) output is fully modulating with a range of6.1 to 24.2kW (20,700 to 82,600 Btu/h)

Instantaneous domestic hot water (DHW) output is also fullymodulating with a maximum of 30.3kW (103,300 Btu/h)

The boiler is supplied fully assembled with DHW plate heatexchanger, diverter valve, circulating pump, pressure gauge,safety valve and CH expansion vessel.

Variable CH and DHW temperature controls are fitted on theuser control and the boiler features a DHW preheat facility.

The boiler includes as standard:- Automatic bypass- Boiler frost protection- Daily pump and diverter valve exercise.

The boiler casing is of white painted mild steel.

The boiler temperature controls are visible located in thecontrol panel on the front of the boiler.

The heat exchanger is manufactured from cast aluminium.

The boiler is suitable for connection to fully pumped, sealedheating systems ONLY. Adequate arrangements for completelydraining the system by provision of drain cocks MUST beprovided in the installation pipework.

Pipework from the boiler is routed downwards.

OPERATIONWith no demand for CH, the boiler fires only when DHW is drawnoff, or periodically for a few seconds without any DHW draw-off, inorder to maintain the DHW calorifier in a heated condition. Thisonly occurs if pre-heat knob is in the ‘ON’ period.

When there is a demand for CH, the heating system issupplied at the selected temperature of between 30oC and80oC, until DHW is drawn off. The full output from the boiler isthen directed via the diverter valve to the plate heat exchanger tosupply a nominal DHW draw-off of 12.4 l/min at 35 oCtemperature rise.

The DHW draw off rate specified above is the nominal that theboiler flow regulator will give. Due to system variations andseasonal temperature fluctuations DHW flow rates/temperaturerise will vary, requiring adjustment at the draw off tap.

At low DHW draw-off rate the maximum temperature is limitedto 64 oC by the modulating gas control.

The boiler features a comprehensive diagnostic system whichgives detailed information on the boiler status when operating,and performance of key components to aid commissioning andfault finding.

SAFE HANDLINGThis boiler may require 2 or more operatives to move it to itsinstallation site, remove it from its packaging base and duringmovement into its installation location. Manoeuvring the boilermay include the use of a sack truck and involve lifting, pushingand pulling.

Caution should be exercised during these operations.

Operatives should be knowledgeable in handling techniqueswhen performing these tasks and the following precautionsshould be considered:

• Grip the boiler at the base.• Be physically capable.• Use personal protective equipment as appropriate, e.g.

gloves, safety footwear.

During all manoeuvres and handling actions, every attemptshould be made to ensure the following unless unavoidableand/or the weight is light.

• Keep back straight.• Avoid twisting at the waist.• Avoid upper body/top heavy bending.• Always grip with the palm of the hand.• Use designated hand holds.• Keep load as close to the body as possible.• Always use assistance if required.

OPTIONAL EXTRA KITS• Telescopic Concentric Flue B pack

• Electronic Timer (7 day) kit

• RF Electronic Programmable Room Thermostat kit

• Stand Off kit

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GENERAL

SAFETYCurrent Gas Safety (installation and use) regulations or rulesin force:

The appliance is suitable only for installation in GB and IE andshould be installed in accordance with the rules in force.

In GB, the installation must be carried out by a Gas SafeRegistered Engineer. It must be carried out in accordance withthe relevant requirements of the:

• Gas Safety (Installation and Use) Regulations

• The appropriate Building Regulations either The BuildingRegulations, The Building Regulations (Scotland), BuildingRegulations (Northern Ireland).

• The Water Fittings Regulations or Water byelaws inScotland.

• The Current I.E.E. Wiring Regulations.

Where no specific instructions are given, reference should bemade to the relevant British Standard Code of Practice.

In IE, the installation must be carried out by a Registered GasInstaller (RGII) and installed in accordance with the currentedition of I.S.813 "Domestic Gas Installations", the currentBuilding Regulations and reference should be made to thecurrent ETCI rules for electrical installation.

Detailed recommendations are contained in the followingBritish Standard Codes of Practice:

BS. 5440:1 Flues (for gas appliances of rated input notexceeding 70 kW).

BS. 5440:2 Ventilation (for gas appliances of rated input notexceeding 70 kW).

BSEN. 12828:2003 Heating Systems in buildings: Design forwater based heating systems.

BSEN 12831:2003 Heating Systems in buildings: Method forcalculation of the design heat load.

BSEN 14336:2004 Heating Systems in buildings: Installationand commissioning of water basedheating systems.

BS. 5546 Installation of gas hot water supplies fordomestic purposes (2nd Family Gases)

BS. 6798 Installation of gas fired hot water boilers of ratedinput not exceeding 70 kW.

BS. 6891 Low pressure installation pipes.

Health & Safety Document No. 635.

The Electricity at Work Regulations, 1989.

The manufacturer’s notes must NOT be taken, in any way, asoverriding statutory obligations.

IMPORTANT. These appliances are CE certificated for safetyand performance. It is, therefore, important that no externalcontrol devices, e.g. flue dampers, economisers etc., aredirectly connected to these appliances unless covered by theseInstallation and Servicing Instructions or as otherwiserecommended by Keston in writing. If in doubt please enquire.

Any direct connection of a control device not approved byKeston could invalidate the certification and the normalappliance warranty. It could also infringe the Gas SafetyRegulations and the above regulations.

SAFE HANDLING OF SUBSTANCESNo asbestos, mercury or CFCs are included in any part of theboiler or its manufacture.

LOCATION OF BOILERThe boiler must be installed on a flat and vertical internal wall,capable of adequately supporting the weight of the boiler andany ancillary equipment.

The boiler may be fitted on a combustible wall and insulationbetween the wall and the boiler is not necessary, unlessrequired by the local authority.

For electrical safety reasons there must be no access availablefrom the back of the boiler.

The boiler must not be fitted outside.

Timber Framed Buildings

If the boiler is to be fitted in a timber framed building it should befitted in accordance with the Institute of Gas Engineeringdocument IGE/UP/7:1998.

Bathroom Installations

This appliance is rated IP20.

The boiler may be installed in any room or internal space,although particular attention is drawn to the requirements of thecurrent IEE (BS.7671) Wiring Regulations and the electricalprovisions of the building regulations applicable in Scotland,with respect to the installation of the boiler in a room or internalspace containing a bath or shower. For IE reference should bemade to the current ETCI rules for electrical installations and I.S.813:2002.

If the appliance is to be installed in a room containing a bath orshower then, providing water jets are not going to be used forcleaning purposes (as in communal baths/showers), the appliancemust be installed beyond Zone 2, as detailed in BS.7671.

0.6m

Zone 0

Recessed

window

Zone 2

Ceiling

3G8913a

2.25m

Zone 1

Compartment Installations

A compartment used to enclose the boiler should be designedand constructed specially for this purpose.

An existing cupboard or compartment may be used, providedthat it is modified for the purpose.

In both cases, details of essential features of cupboard /compartment design, including airing cupboard installation,are to conform to the following:

• BS 6798 (No cupboard ventilation is required - see ‘AirSupply’ for details).

• The position selected for installation MUST allow adequatespace for servicing in front of the boiler.

• For the minimum clearances required for safety andsubsequent service, see the wall mounting template andFrame 1. In addition, sufficient space may be required toallow lifting access to the wall mounting plate.

• The boiler must be installed on a fire resistant surface.

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GENERAL

GAS SUPPLYThe local gas supplier should be consulted, at the installationplanning stage, in order to establish the availability of anadequate supply of gas. An existing service pipe must NOT beused without prior consultation with the local gas supplier.

The boiler MUST be installed on a gas supply with a governedmeter only.

A gas meter can only be connected by the local gas supplier orby a Gas Safe Registered Engineer. In IE by a Registered GasInstaller (RGII).

An existing meter should be checked, preferably by the gassupplier, to ensure that the meter is adequate to deal with therate of gas supply required.

It is the responsibility of the Gas Installer to size the gasInstaller to size the gas installation pipework in accordancewith BS6891:2005. Whilst the principle of the 1:1 gas valveensures the Keston 30C is able to deliver its full output at inletpressures as low as 14mb, other gas appliances in theproperty may not be as tolerant. When operating pressures arefound to be below the minimum meter outlet of 19mb theseshould be checked to ensure this is adequate for correct andsafe operation.

Allowing for the acceptable pressure loss of 1mb across theinstallation pipework, it can be assumed that a minimumpermitted operating pressure of 18mb will be delivered to theinlet of the appliance. (Reference BS 6400-1 Clause 6.2Pressure Absorption).

The integral appliance isolation valve and boiler pipeworkcould further reduce the operating pressure by up to 1.5mbwhen measured at the inlet test point on the appliance gasvalve. Therefore it has been identified that an operatingpressure as low as 16.5mbar could be measured at theappliance inlet pressure test point on the gas valve.

IMPORTANT.Installation pipes must be fitted in accordance with BS.6891. InIE refer to IS.813:2002.

The complete installation MUST be tested for gas tightnessand purged as described in the above code.

WATER CIRCULATION SYSTEMIMPORTANT.A minimum length of 1 metre of copper pipe MUST be fitted toboth flow and return connections from the boiler beforeconnection to any plastic piping.

The central heating system should be in accordance withBS.6798 and, in addition, for smallbore and microboresystems, BS.5449.

WATER TREATMENT - see Frame 5

BOILER CONTROL INTERLOCKSCentral heating systems controls should be installed to ensurethe boiler is switched off when there is no demand for heating,in compliance with Building Regulations.

Heating systems utilising full thermostatic radiator valve controlof temperature in individual rooms should also be fitted with aroom thermostat controlling the temperature in a space servedby radiators not fitted with such a valve.

When thermostatic radiator valves are used, the space heatingtemperature control over a living / dining area or hallway havinga heating requirement of at least 10% of the minimum boilerheat output should be achieved using a room thermostat,whilst other rooms are individually controlled by thermostaticradiator valves. However, if the system employs thermostaticradiator valves on all radiators, or two port valves, then abypass circuit must be fitted with an automatic bypass valve toensure a flow of water should all valves be in the closedposition.

ELECTRICAL SUPPLYWARNING.This appliance must be earthed.Wiring external to the appliance MUST be in accordance withthe current I.E.E. (BS.7671) Wiring Regulations and any localregulations which apply. For IE reference should be made tothe current ETCI rules for electrical installations.

The mains supply to the boiler and system wiring centre shallbe through one common fused double pole isolator and fornew heating systems, and where practical replacement boilerinstallations, the isolator shall be situated adjacent to theappliance.

CONDENSATE DRAINRefer to Frames 15, 25 & 48

A condensate drain is provided on the boiler. This drain mustbe connected to a drainage point on site. All pipework andfittings in the condensate drainage system MUST be made ofplastic - no other materials may be used.

IMPORTANT.Any external runs must be in accordance with BS 6798.

The drain outlet on the boiler is sized for standard 21.5mm (3/4”)overflow pipe. It is a universal fitting to allow use of differentbrands of pipework.

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GENERAL

1 BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm

The boiler connections are made on the boiler connectiontails. Refer to Frames 27-30.

The following minimum clearances must be maintained foroperation and servicing.

Additional space will be required for installation, dependingupon site conditions.

Front clearanceThe minimum front clearance when built in to a cupboard is5mm from the cupboard door but 450mm overall clearance isstill required, with the cupboard door open, to allow for servicing.

* Bottom clearanceBottom clearance after installation can be reduced to 5mm.This must be obtained with an easily removable panel, toenable the consumer to view the system pressure gauge, and toprovide the 100mm clearance required for servicing.

3G10

044b

395

30mmMinimum Top Clearance

100395

400

700

Flue Air

2.52.5from case

*

43 65 57 38

Gas Inlet

39 65

3G10051

Flue

Air

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GENERAL

General

1. The installation must comply with all relevant national andlocal regulations.

2. The installation should be designed to work with flowtemperatures of up to 86

oC.

3. All components of the system must be suitable for a workingpressure of 3 bar and temperature of 110

oC. Extra care should

be taken in making all connections so that the risk of leakageis minimised.

The following components are incorporated within theappliance:

a. Circulating pump.

b. Safety valve, with a non-adjustable preset lift pressure of 3 bar.

c. Pressure gauge, covering a range of 0 to 4 bar.

d. An 8-litre expansion vessel, with an initial charge pressureof 0.75 bar.

4. 'Make-up' Water. Provision must be made for replacing waterloss from the system, either :

a. From a manually filled 'make-up' vessel with a readilyvisible water level. The vessel should be mounted atleast 150mm above the highest point of the system andbe connected through a non-return valve to the system,fitted at least 150mm below the 'make-up' vessel on thereturn side of the radiators. or

b. Where access to a 'make-up' vessel would be difficult, bypre-pressurisation of the system.

The maximum cold water capacity of the system shouldnot exceed 143 litres, if not pressurized. However, if thesystem is to be pressurized, the efficiency of theexpansion vessel will be reduced and a larger vessel(or smaller system volume) may be necessary. If thecapacity of the vessel is not considered sufficient forthis, or for any other reason, an additional vessel MUSTbe installed on the RETURN to the boiler.

Guidance on vessel sizing is given in Table above.

Notes

a. The method of filling, refilling, topping up or flushing sealedprimary hot water circuits from the mains via a temporary hoseconnection is only allowed if acceptable to the local waterauthority.

b. Antifreeze fluid, corrosion and scale inhibitor fluids suitablefor use with boilers having aluminium heat exchangers maybe used in the central heating system.

2 SYSTEM REQUIREMENTS - Central Heating

Water Flow Rate and Pressure Loss

Max CH Output kW 24.2(Btu/h) (82,600)

Water flow rate l/min 17.3(gal/min) (3.8)

Temperature Differential oC 20(oF) (36)

Head available for m.w.g. 3.4system (ft.w.g.) (11.1)

Safety valve setting bar 3.0

Vessel charge pressure bar 0.5 to 0.75

System pre-charge pressure bar None 1.0

System volume Expansion vessel(litres) volume (litres)

25 1.6 1.8

50 3.1 3.7

75 4.7 5.5

100 6.3 7.4

125 7.8 9.2

150 9.4 11.0

175 10.9 12.9

190 11.9 14.0

200 12.5 14.7

250 15.6 18.4

300 18.8 22.1

For other system volumesmultiply by the factor across 0.063 0.074

5. Filling

The system may be filled by the following method:

Where the mains pressure is excessive a pressurereducing valve must be used to facilitate filling.

a. Thoroughly flush out the whole system with coldwater.

b. Fill and vent the system until the pressure gaugeregisters 1bar and examine for leaks. Refer toFrame 33 for filling detail.

c. Check the operation of the safety valve by raisingthe water pressure until the valve lifts. This shouldoccur within 0.3bar of the preset lift pressure.

d. Release water from the system until theminimum system design pressure is reached;1.0 bar if the system is to be pre-pressurised.

continued . . . . . .

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GENERAL

The boiler does not normally need a bypass but at least some radiators on the heating circuit, of load of at least 10% of theminimum boiler output, must be provided with twin lockshield valves so that this minimum heating load is always available.See note regarding thermostatic radiator valves on page 8.

Note. Systems incorporating zone valves which could completely cut off the flow through the system must also include abypass.

4 SYSTEM BALANCING

BALANCING1. Set the programmer to ON.

Close the manual or thermostatic valves on allradiators, leaving the twin lockshield valves (on theradiators referred to above) in the OPEN position.

Turn up the room thermostat and adjust the lockshieldvalve to give an uninterrupted flow through the radiator.

These valves should now be left as set.

3 SYSTEM REQUIREMENTS - CH (continued) and Hot Water

DOMESTIC HOT WATER1. The domestic hot water service must be in accordance

with BS 5546 and BS 6700.

2. Refer to Table 1 for minimum and maximum workingpressures. In areas of low mains water pressures thedomestic hot water regulator may be removed from theDHW flow turbine cartridge. Refer to Frame 76. The boilerwill require the flow rate to be set to obtain a temperaturerise of 35oC at the tap furthest from the boiler.

3. The boiler is suitable for connection to most types ofwashing machine and dishwasher appliances.

4. When connecting to suitable showers, ensure that:

a. The cold inlet to the boiler is fitted with an approvedanti-vacuum or syphon non-return valve.

b. Hot and cold water supplies to the shower are of equalpressure.

5. Hard Water AreasWhere the water hardness exceeds 200mg/litre, it isrecommended that a proprietary scale reducing device isfitted into the boiler cold supply within the requirements ofthe local water company.

IMPORTANTProvision MUST be made to accommodate the expansion ofDHW contained within the appliance, if a non-return valve isfitted to the DHW inlet, or a water meter with a non-return valveis installed.

2. Open all manual or thermostatic radiator valves andadjust the lockshield valves on the remaining radiators,to give around 20oC temperature drop at each radiator.

3. Adjust the room thermostat and programmer toNORMAL settings.

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GENERAL

5 WATER TREATMENT

CENTRAL HEATINGThe Keston 30C boiler has an ALUMINIUM alloy heatexchanger.

IMPORTANT.The application of any other treatment to this productmay render the guarantee of Keston Invalid.

Keston recommend Water Treatment in accordance withthe Benchmark Guidance Notes on Water Treatment inCentral Heating Systems.

If water treatment is used Keston recommend only the use ofFERNOX, MBI or SENTINEL X100 inhibitors and associated watertreatment products, which must be used in accordance withthe manufacturers' instructions.

Notes.

1. It is most important that the correct concentration of thewater treatment products is maintained in accordance withthe manufacturers' instructions.

2. If the boiler is installed in an existing system any unsuitableadditives MUST be removed by thorough cleansing. BS7593:2006 details the steps necessary to clean a domesticheating system.

3. In hard water areas, treatment to prevent lime scale may benecessary - however the use of artificially softened water isNOT permitted.

4. Under no circumstances should the boiler be fired beforethe system has been thoroughly flushed.

DOMESTIC HOT WATERIn hard water areas where mains water can exceed200ppm Total Hardness (as defined by BS 7593:2006 Table2) a scale reducing device should be fitted into the boilercold supply within the requirements of the local watercompany. The use of artificially softened water, however, isnot permitted.Keston recommend the use of Fernox Quantomat, SentinelCombiguard and Calmag CalPhos I scale reducingdevices, which must be used in accordance with themanufacturers' instructions.

For further information contact:

Fernox Manufacturing Co. LtdCookson ElectronicsForsyth RoadSheerwaterWokingSurrey GU21 5RZ+44 (0) 1799 521133

Sentinel Performance SolutionsThe Heath Business & Technical ParkRuncornCheshire WA7 4QXTel: 0800 389 4670www.sentinel-solutions.net

Salamander Engineering LtdThe Heath Business & Technical ParkRuncornCheshire WA7 4QXTel: 0800 389 4670

Calmag Ltd.Unit 4-6, Crown WorksBradford RoadSandbeds, KeighleyWest Yorkshire BD20 5LNTel: +44 (0) 1535 210 320

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13

INSTALLATION

Keston 30C - Installation and Servicing

6 BOILER ASSEMBLY - Exploded View LegendNote that item numbers are linked to the spares list

104 CH RETURN VALVE

105 CH FLOW VALVE

106 DHW INLET & OUTLET

107 FILLING LOOP

108 PUMP HEAD

110 AIR VENT PUMP

111 DIVERTER VALVE HEAD

112 DIVERTE R VALVE CARTDRIGE

113 PRESSURE RELIEF VALVE

114 PIPE - PRV OUTLET

115 PIPE - FLOW

116 PIPE - RETURN

117 PIPE - EXPANSION VESSEL

118 EXPANSION VESSEL

119 RETURN GROUP MANIFOLD

120 FLOW GROUP MANIFOLD

121 PLATE HEAT EXCHANGER

127 FLOW SENSOR HALL EFFECT

128 FLOW TURBINE CARTRIDGE

131 WATER PRESSURE TRANSDUCER

135 PRESSURE GAUGE

203 GAS COCK

204 PIPE - GAS INLET

205 GAS VALVE

206 PIPE - GAS INJECTOR

211 INJECTOR ASSEMBLY

214 VENTURI

215 FAN

217 BURNER

218 GASKET - BURNER

219 SUMP CLEAN OUT COVER

223 FLUE MANIFOLD

224 FLUE MANIFOLD TOP

227 CLAMP RETAINING FLUE TURRET

228 HOSE CONDENSATE INTERNAL

229 SIPHON TRAP

230 SIPHON TRAP CAP & SEAL

231 CONDENSATE OUTLET CONNECTION

233 FLUE SENSING NIPPLE

301 CONTROLS BOX FIXINGS HINGE & SPRING

302 PRIMARY PCB

303 CUI BOARD

304 CONTROL THERMISTOR (FLOW / RETURN)

306 ELECTRODE IGNITION

307 ELECTRODE DETECTION

308 IGNITER UNIT

309 THERMISTOR NO FLOW

313 IGNITION LEAD

314 CONTROL BOX LENS

324 CONTROLS BOX LID

325 CONTROL BOX FRONT

326 PROGRAMMER INSERT

401 HEAT ENGINE

503 WALL MOUNTING BRACKET

504 FRONT PANEL

505 FASCIA

506 BRACKET - GAS VALVE

507 BRACKET - EXPANSION VESSEL

136 SAFETY VALVE DRAIN PIPE

512 DROP DOWN DOOR

332 FLUE THERMOSTAT

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14

INSTALLATION


7 BOILER ASSEMBLY - Exploded View (excluding flue box)

BCC3G9971b

227

224

233 503

313

504

505

512

215

217

309

306

308211

304

214

206

205

204

223 332

326325 302

104

110

114

113

136

121

118

507

131128

127

120

119

117

106203106

107

135

105

111231

112228

229

303

304

116115

219

301

401

218

307

230

324

108

314

506

30C

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15

INSTALLATION


8 UNPACKING

The boiler is supplied fully assembled in Pack 1, together with Pack 2 for flue lengths up to 450mm.

Unpack and check the contents.

Pack 1 Contents

A Boiler

B Hardware Pack Box

C Wall Mounting Plate

D These Installation Instructions(includes Warranty/Guarantee)

E Wall Mounting Template(located on internal protectivepackaging)

F Turret Clamp

G Safety Valve Drain Pipe

H Weather Compensator

continued . . . . .

C

A

D F

G

H

BEE

3G10046a3G10046a

30C

HARDWARE PACK CONTENTS

Gas Valve Pack

1. Pipe - Gas Inlet

2. Washer - Gas (blue)

3. Gas Cock

Filling Loop Pack

1. 3/8" Fibre washer (x4)

2. Valve (double check valve) fitting

3. Valve - Filling Loop

4. Plastic Chain (x2)

5. Filling Loop

6. 3/8" Blanking Rubber Washer (x2)

Return Valve Pack

1. Pipe CH Return

2. Washer CH

3. Valve Return

DHW Pack

1. Pipe DHW Outlet

2. Valve - Return DHW

3. Washer DHW (x2)

4. Pipe DHW Inlet

5. Nut 1/2"

Accessory Pack

1. Screw (x2)

2. Wallplug (x2)

Flow Valve Pack

1. Pipe CH Flow

2. Washer CH

3. Valve Flow (with gauge)

Gas Valve Pack DHW Pack

Accessory Pack

Flow Valve Pack

Return Valve Pack

Filling Loop

1 1

1

11

5

2

3

3

3

1

2 3

46

5

4

2

2

2

2

3

3

3G9687

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16

INSTALLATION


Pack 2a Contents

1. 3 x elbows

2. 2 x 450mm pipe

3. 3 x 100mm pipe

Pack 2 Contents

2 Boxes

Pack 2b Contents

1. Top Flue Box

2. 6 x screws

3. 2 x Terminals

1

2

3

1 2 3

8 UNPACKING....CONT’D

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INSTALLATION


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MAXIMUM LENGTHSThe maximum lengths of both air inlet pipe and flue outlet pipe,when no bends are used, are as detailed in fig.2b.

However, each bend used has an equivalent length that must bededucted from the maximum straight length stated in fig. 2b.Knuckle bends must not be fitted.

A 92.5º swept elbow is equivalent to 1.0m straight length. A 45ºbend is equivalent to 0.5m straight length.

It is possible to have variable flue and air lengths as detailedbelow.

Fig. 2b

(does not include allowance for elbow on top of boiler)

Example (assuming 50mm muPVC flue and air pipework)

Air inlet uses two 92.5º swept elbows. Hence, maximum lengthpermissible (i.e. a+b in fig. 2a) = 22m - 1m - 1m = 20m.

Flue outlet uses one 92.5º swept elbow. Hence, maximumlength permissible (i.e. c+d in fig. 2a)= 22m - 1m = 21m).

But maximum total flue and air intake must not exceed 19m inthe examples above.

Boiler Output Vs Flue Length

Due to the resistance presented by extended flue length a slightreduction in maximum boiler output will occur where combinedflue and air lengths in excess of 16.0m (50mm muPVC) areused. In such cases the boiler output will be reduced by 1.0%per additional metre.

9 FLUE SYSTEMNote. When installing a replacement boiler a new fluesystem must be used. Do not re-use the existing boiler flueinstallation.

DESIGNIndividual air supply and flue outlet pipes are used asstandard, although a concentric flue kit is available as anoptional extra.

The material used for flue outlet &/or air inlet must bemuPVC (PVC-C) to BS 5255 and/or BSEN 1566-1 and BSEN1329 of an internal diameter of 51mm. (i.e. nominal 50mmdiameter muPVC solvent weld waste pipe).

Marley muPVC (PVC-C) Solvent Weld Waste System(50mm) and Polypipe System 2000 muPVC (PVC-C) solventweld waste (50mm) are the only systems approved for thisapplication.

The following pipes and fittings are approved:

Polypipe System 2000 muPVC solvent Weld Waste System (50mm)

Poly Pipe Code

MU 301 4m length muPVC wastepipe 5/225

MU 313 50mm x 45 deg muPVC obtuse bend

MU 314 50mm x 92.5 deg muPVC swept bend

MU 310 50mm muPVC straigh coupling

MU 316 50mm x 92.5 deg muPVC swept pipe

Marley muPVC solvent Weld Waste System (50mm) Marley Code

KP 304 50mm x 4m double spigot pipe

KP32 50mm x 45 deg bend

KSC3 50mm straight coupling

KB3 50mm x 88.5 deg bend

KT3 50mm swept tee

Maximum Combined Flue & Air Intake Lengths

Air Inlet 21m

Flue Outlet 21m

Total Flue & Air Intake 22m

Fig.1

FLUE AIR

c a

Flue Box

db

KESTON 30C

3G10

025

Fig.2aWhen the flue and air terminals arelocated within 500mm of each otherensure that the air terminal ispointing towards the ground usinga 90º bend and one of the 100mmsections of pipe provided withinpack 2a.

Both the 50mm flue outletterminal and the 50mm air inletterminal are supplied with thetwin flue box (pack 2b) and areillustrated in Fig. 1 and must beused in ALL installations. (Bothterminals are identical).

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INSTALLATION


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09 FLUE SYSTEM.... CONT’D

SLOPE‘Horizontal’ flue outlet pipework MUST slope at least 2 degrees(32mm per metre run) downwards towards the boiler. Pipeworkcan be vertical. Only swept elbows can be used.

Air inlet pipework can be truly horizontal or vertical, or sloping ina downward direction towards the boiler but in each case rain,etc., must be prevented from entering the pipe. There must beno troughs in any of the pipework, whether it be air inlet orflue outlet.

Due to the low temperature of the flue gases furthercondensate will form within the flue system. Drain points, withsuitable traps, must therefore be incorporated within the fluesystem at the base of the vertical flue sections in excess of 6m,for 50mm muPVC pipe flue systems. These additionalcondensate drains must be run to discharge. Such drain pointscan be formed using standard muPVC fittings. Refer to fig. 3.

TERMINATIONSAir inlet terminals must be facing horizontally or downwards toprevent entry of rain into the terminal and positioned to ensureonly fresh air is drawn into the boiler. The air terminal must belocated outside of the building. Flue terminals must bepositioned so that flue products are not drawn into the air inlet.Site specific wind conditions should be considered to achievethis. Drawing of combustion air directly from a ventilated boilerroom invalidates the heat exchanger warranty.

The flue outlet terminal is designed to face outwards and mustnot be directed in the region of the air inlet. The flue terminaland air inlet terminal can be located on different, but notopposing wall faces.

The two terminals are subject to the requirements of BS 5440Pt 1 for clearances from features of the building although somecan be decreased to the values indicated.

The Keston 30C, as with any condensing boiler, will generate acondensate “plume” from the flue terminal in all weatherconditions. Consideration must therefore be given to the effectof this “plume” when selecting a location for the flue terminal. Itis the responsibility of the installer to ensure the selectedterminal location does not cause nuisance.

If either the air inlet or flue outlet terminate at a height of lessthan 2.1m above ground level, the terminal must be protectedby a suitable guard. The K6 terminal guard (with plasticcoating), manufactured by Tower Flue Components Ltd issuitable for this purpose.

300300L Horizontally from terminal on same wall.1,5001,500K Vertically from terminal on same wall.1001,200J From opening in a car port.(not recommended)

1,2001,200I From terminal facing a terminal.100600H From surface or boundary facing a terminal. *100300G Above ground or balcony or roof.

50200F From internal or external corner or to aboundary alongside the terminal. *

5075E From vertical drain or soil pipes.50200D Below balconies or car port roof (lowest point).50200C Below eaves.7575B Below gutters, soil pipes, drain pipes.

50300A Below, above or beside openable window, airbrick, etc.

AirInlet

FlueTerminalDimensions (mm)

3G10

028a

*The dimensions given in the table above may need to beincreased to avoid wall staining and nuisance depending onsite conditions.

CLEARANCES FROM WALLFlue outlet and air inlet terminations must be at least 40mmfrom the wall face.

DISTANCE BETWEEN FLUE OUTLET & AIRINLETThere is no maximum - the terminations must not be onopposite sides of the dwelling but can be in areas of unequalpressure.

A minimum clearance of at least 500mm must be left betweenthe terminations otherwise a 90º elbow MUST be fitted to airinlet and pointed towards the ground. The absolute minimumclearance between the flue and air terminals is 100mm.

GENERAL INSTALLATIONSAll parts of the system must be constructed in accordance withBS 5440 Part 1, except where specifically mentioned in theseinstructions.

All pipework must be adequately supported.

All joints other than approved push-on or plastic compressionconnectors must be made and sealed with solvent cementsuitable for muPVC pipes and conforming to BS 6209: 1982.

Consideration must be given to Corgi/Gas Safe bulletin TB200/TB008 regarding flues in voids.

The boiler casing must always be correctly fitted to the boilerwhen leaving the appliance operational.

External wall faces and any internal faces of cavity walls mustbe good.

Rubber collars are available for flue and air terminals to finishthe external wall face around the terminals (Part NoC.08.00.07.0).

AIR SUPPLYThe Keston 30C is a room sealed appliance and thereforedoes not require purpose provided ventilation to the boiler roomfor combustion air.

COMPARTMENT INSTALLATIONDue to the low casing temperatures generated by the boiler, nocompartment ventilation is required. However, the cupboard orcompartment must not be used for storage.

6 in min.

Tee FittingTo Boiler

To T

erm

inal

Fig.3

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19

INSTALLATION


10 INSTALLING THE BOILERInstallation of the boiler is straightforward but consideration must be given to access to allow flue and air pipes to be pushedthrough walls and ceilings. The order in which the components are installed will depend upon particular site conditions, but ingeneral it will be easiest and most accurate to install the boiler and then build up the flue outlet and air inlet pipes to the terminal- this is the sequence described.

The wall mounting template is located on the internalprotective packaging.

Note.The template shows the positions of the fixing holes andthe position that the twin flue box is located. Care MUSTbe taken to ensure the correct holes are drilled.

1. Tape template into the selected position. Ensuresquareness by hanging a plumbline as shown.

2. Mark onto the wall the following:

a The wall mounting plate screw positions (choose onefrom each group).

b The position of the air and flue when exiting straight outof the wall where the boiler is mounted.

Note. Mark the centre of the hole as well as thecircumference.

3. Remove the template from the wall.

11 WALL MOUNTING TEMPLATE

3G10056

12 PREPARING THE WALL

IMPORTANT.

Ensure that, during the cutting operation, masonry fallingoutside of the building does not cause damage or personalinjury.

1. Cut the flue and air holes (preferably with 60mm corebore tool) ensuring the holes are square to the wall.

2. Drill 2 holes with a 7.5mm / 8mm masonry drill andinsert the plastic plugs, provided, for the wall mountingplate.

3. Locate 2 No.14 x 50mm screws in the wall mountingplate (one at each side, in any of the 3 holes provided ateach side) and screw home.

3G10

030

X

Sectionthrough wall

Note. Check all of the holepositions before drilling.

Rear flue only60mm diameterholes

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INSTALLATION


15 CONDENSATE DRAIN

Ensure that the siphon is full of water beforecommissioning the boiler. Refer to Frame 26.

The routing of the drain must be made to allow aminimum fall of 1 in 20 away from the boiler, throughoutits length.

The drainage pipework must be arranged so thatobstruction (e.g. through freezing) of external drainagepipe does not give rise to spillage within the dwelling.

IMPORTANT.All pipework and fittings in the condensate drain systemmust be made of plastic. No other materials may beused.

The drain outlet on the boiler is standard 21.5mmoverflow pipe and is suitable for either push fit orsolvent weld applications. This size must not bereduced in any part of its length.

The boiler includes as standard, a 75mm condensatetrap. The condensate trap also includes a siphon toreduce the possibility of freezing in the drain outlet.

If external condensate pipe is used then the pipeshould be 32mm nominal diameter. Considerationshould be given to insulating external condensate piperuns.

esp9496

Example of fixing

14 MOUNTING THE BOILER

1. Ensure the plastic plugs are removed from both the CHand DHW connections before mounting the boiler.

2. Lift the boiler onto the wall mounting plate (refer to theIntroduction section for safe handling advice), locating itover the two tabs.

3G

99

74

30C

13 FITTING THE WALL MOUNTING PLATE

Screw the wall mounting plate to the wall using 2 wall plugs(previously fitted) with the 2 screws provided.

Choose one of the 2 sets of slots in left and right bank.Ensuring that at least one of the screws is fitted into a topslot.

IN

STA

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21

INSTALLATION


Retaining Clip(assembled)

3G10101

Clamp

M5 Screw

Air Spigot

Flue Spigot

16 ASSEMBLY PRACTICERemove all plastic debris and burrs when installing air intakepiping. Plastic fillings caused by cutting muPVC pipe must notbe allowed to be drawn into the combustion air blower. Preventdust entering the air intake when cutting on building sites.Blower failure which is determined to be caused by plasticfilings or other debris will not be covered by guarantee.

INSTALLING FLUE AND AIR PIPES ONTOTHE TWIN FLUE BOXImportant - When installing the boiler on an existing system anew flue and air intake system MUST also be installed. YouMUST NOT re-use existing flue or air pipework components.

• Remove the twin flue box from Pack 2b supplied withthe boiler.

• Remove boiler front panel - Frame 45

• Position flue box on top of the boiler (see diagram)

• Clamp onto boiler using horseshoe clamp provided inboiler packaging box.

• Fix box to the boiler top panel using 6 x M5 screwsprovided.

• Measure, cut and check the air and flue pipes to pass tothe exit from the wall(s) or ceiling.

• Always thoroughly deburr all pipes and mostimportant, remove shavings from within the pipe.

• Assemble, using solvent weld cement, the pipeworkfrom the boiler connections to the exit from the first wall/ceiling, (remount the boiler if removed). When pushingpipe through walls, ensure grit and dust is not allowedto enter the pipe.

Ensure pipes are fully engaged into sockets andsolvent welded with no leaks.

• Using the same methods drill any further holes (alwayscovering existing pipework), cut and assemble thepipework.

• From outside, complete the two terminations - SeeFrame 9 Flue System and make good all holes. (Wallsealing collars are available to make good hole areason the wall face (part number C.08.0.00.07.0).

• Support any pipes whose route could be displacedeither of its own accord or by accident. Any horizontalrun over 1m or vertical runs of any length must alwaysbe supported. Brackets should be placed at intervalsof approximately 1m. Brackets should be looseenough on the pipe to allow thermal expansion andcontraction movement.

• Flue pipework through walls MUST be sleeved to allowthermal expansion and contraction movement.

• Check all connections for security and re-seal any jointsusing solvent cement where soundness may be indoubt.

Note. It is equally important to seal the air inlet with solventcement as the flue outlet pipe joints.

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INSTALLATION


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FLUE KITS

Pack B - telescopic supplied as an optional extra

Concentric Flue Screw Retaining Kit - optional kit formechanical fixing of flue joints.

Finishing Kit - Supplied as an optional extra.

Refer to 'Flue Extension Ducts'

Where a concentric flue option is chosen the following instruction should be followed and the standard flue in flue boxomitted.

Dimension X - Wall thickness.

Dimension L - Wall thickness plus boiler spacing.

Dimension S - Optional stand-off frame depth 45mm.

17 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED FORCONCENTRIC OPTION KIT

MAXIMUM HORIZONTAL FLUE LENGTH = 575MMMINIMUM HORIZONTAL FLUE LENGTHS - TELESCOPIC TERMINAL = 350MM(Centre Line of turret to outside of wall terminal)

197mm 197mm

Wall Thickness X

Side flue length L

SIDE FLUEREAR FLUE

IMPORTANT. The boiler MUST be installed in a vertical position

Only use Keston concentric flue pipe and fittings.

1. If the telescopic B pack is used, they may be mountedhorizontally. The 1.5 degrees is taken care of by theinclination of the flue within the air pipe.

2. Only use water as a lubricant during assembly.

Total Flue length dimension(measuring from CL of turret to outside wall)

Rear flue Side fluedim. X+155 dim. L+197

Up to 575 mm Up to 575 mm

Note: All other clearances as per Twin Flue Application (See Frame1)

155 + S = 200mm

3G94

93a

165mmMinimum Top

Clearance

Wall Thickness X

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INSTALLATION


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18 TERMINAL WALL SEAL ASSEMBLY / POSITIONING - CONCENTRIC FLUE OPTION

Ensure lip of wall seal is positioned

over step on plastic nose of flue terminal(note, seal is cut away for clarity)

Step

isfu9783

Wall Seal Lip

Prior to fitting the flue, the rubber terminal wall seal providedin the flue pack MUST be fitted to the flue terminal as shownbelow in Figure 1.

FIGURE 1 FIGURE 2

Once the flue is installed it is IMPORTANT that the rubberterminal wall seal is pressed against the outside wall tocreate an adequate seal between the flue and wall asshown in Figure 2.

var9

784

Rubber

Terminal

Wall Seal

19 FLUE ASSEMBLY - CONCENTRIC FLUE OPTION - Exploded View

An optional flue duct extension kit isrequired for wall thicknesses greaterthan :

Side 378mm

Rear 420mm

LEGEND

1. Duct assembly.

2. Flue turret.

3. Turret clamp.

The flue terminal MUSTbe fitted with the ‘TOP’uppermost to allow thecorrect fit and use of theplume managementsystem.

TOP

3G9499a

3

2

1

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INSTALLATION


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The wall mounting template is located on the internalprotective packaging.

Note.The template shows the positions of the fixing holes andthe position that the twin flue box is located. Care MUSTbe taken to ensure the correct holes are drilled.

1. Tape template into the selected position. Ensuresquareness by hanging a plumbline as shown.

2. Mark onto the wall the following:

a The wall mounting plate screw positions (choose onefrom each group).

b The position of the air and flue when exiting straight outof the wall where the boiler is mounted.

Note. Mark the centre of the hole as well as thecircumference.

3. Remove the template from the wall.

20 WALL MOUNTING TEMPLATE - CONCENTRIC FLUE OPTION

3G10056

21 PREPARING THE WALL - CONCENTRIC FLUE OPTION

IMPORTANT.

Ensure that, during the cutting operation, masonry fallingoutside of the building does not cause damage or personalinjury.

1. Cut the flue hole (preferrably with 5” core bore tool forconcentric), ensuring that the hole is square to the wall.Both wall faces immediately round the cut hole shouldbe flat.

2. Drill 2 holes with a 7.5mm / 8mm masonry drill andinsert the plastic plugs, provided, for the wall mountingplate.

3. Locate 2 No.14 x 50mm screws in the wall mountingplate (one at each side, in any of the 3 holes provided ateach side) and screw home.

3G

9495

X

Section

through wall

Note. Check all of the hole

positions before drilling.

Side flue only

5" diameter hole

Rear flue only

5" diameter hole

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INSTALLATION


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22 SETTING THE FLUE - REAR - CONCENTRIC FLUE OPTION

Notes.

a. If the stand-off frame is used it is essential to add45mm to ‘X’ the measured wall thickness whenmarking the flue (this will allow for the fitted frame).

1. Measure and note wall thickness X. Refer to Frame17.

2. Add 75mm to dimension X and set telescopic fluelength as indicated in drawing.

3. Using a 3.5mm drill bit, drill one hole in outer air ducttaking care not to pierce plastic inner flue.

4. Fix to length using self tappers provided.

5. Seal outer air duct using the tape provided.

nm8944

X + 75

Drill holeAdhere sealing tape

Measurement to be

taken from this point

TELESCOPIC FLUE - Wall thickness of 195mm to 420mm

23 SETTING THE FLUE - SIDE - CONCENTRIC FLUE OPTION

1. Measure and note wall thickness X. Refer to Frame 17.

2. Measure distance from side of boiler to inside of walland add to wall thickness X=L. Refer to Frame 17.

3. Add 115mm to dimension L and set telescopic fluelength as indicated in drawing.

4. Using a 3.5mm drill bit, drill one hole in outer air ducttaking care not to pierce plastic inner flue.

5. Fix to length using self tappers provided.

6. Seal outer air duct using the tape provided.

nm8945

L + 115

Drill holeAdhere sealing tape

Measurement to be

taken from this point

TELESCOPIC FLUE - Wall thickness of 150mm to 375mm

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26

INSTALLATION


1. INTERNAL TO SINK WASTEUPSTREAM OF SINK WASTE TRAP

Notes: ALL EXTERNAL PIPE RUNS MUST BE IN ACCORDANCE WITH BS 6798

24 CONDENSATE PIPE TERMINATION CONFIGURATIONS

2. INTERNAL CONNECTION TO SOIL AND VENT STACK

* Make connection to SVP using a solvent welded saddle

BOILER

External

wall

Ground Level

Open end of pipe

direct into gulley

below grating but

above water level

DRAIN

cla7775

3. TERMINATION TO SOAK AWAY 4. TERMINATION TO DRAIN / GULLY

BOILER

External

wall

Ground Level

Termination

to Soak away

cla7774

minimum

500mm

BOILER

esp8882

BOILER

cla7771a

DRAIN

Ground Level

Open end of pipe

direct into gulley

below grating but

above water level

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INSTALLATION


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25 CONNECTING THE CONCENTRIC FLUE OPTION TO THE BOILER

Notes.

• Before fitting the flue turret fill the condensate trap withinthe boiler by pouring a cupful of water into the flue outlet(shown below). Take care to ensure that the water is onlypoured into the flue outlet, and does not spill into theboiler casing.

• During assembly check that flue seals do not becomedislodged.

1. Ensure front panel is removed.

2. Locate the flue into the turret.

3. Insert the flue assembly throughthe prepared hole in the wall. Pushthrough and pull back to sealagainst outside wall face.

4. Locate the flue turret into the fluemanifold and secure by applyingdownward pressure.

5. Engage the clamp in its slidemechanism and push it horizontallybackwards

6. Locate BOTH plastic pegs BEFOREthe front retaining clip is fullylocated.

Note - Flues over 1 metre long

It is recommended that a supportbracket is fitted for every 1 metre ofextension pipe used and a bracketshould be used at every joint, to ensurepipes are held at the correct angle.

2

3G9847a

3

3G9847b

4

3G9847cFlue Outlet

3G9847d

5

3G9847e

6

Plastic Pegs

(assembled)

Retaining Clip

(assembled)

3G10115

NOTE. SIDE FLUESelect flueorientation beforeinserting turret intoboiler manifold.

DO NOT twist theturret once inserted.

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28

INSTALLATION


Black

Handle Yellow

Handle

Black

Handle

Black

Handle

Blue

Handle

3G9849a

CH Flow

CH

Return2

1

27 WATER CONNECTIONS - DHW

1. Fit the DHW inlet service valve (blue handle) and coppertail to the threaded boss connection ensuring the sealprovided is correctly located.

2. Fit DHW outlet pipe tail to DHW outlet connection,ensuring the seal provided is correctly located.

26 WATER CONNECTIONS - CH

NOTES.Ensure all boss blanking plugs are removed beforeconnecting hardware. Each valve must be fitted to thecorrect boss as shown in the picture.

Ensure each union is fitted with fibre sealsprovided.

Do not subject any of theisolating valves to heat asthe seals may be damaged.

3. Fit the filling loop provided between the DHW inlet valveand the CH return valve.

Note that all isolation handles are shown inthe open position.

1. Connect the CH flow service valve and copper tail providedin the hardware pack to the threaded boss connectionprovided at the lower rear of the boiler.

2. Connect the CH return valve (black handle) and copper tail.

3. If connecting the boiler to heating loads in excess of 60,000Btu/h, connecting flow and return heating system pipeworkmust be sided in 28mm diameter at the point of pipeconnection to the boiler tails. Use 22mm x 28mm pipeadaptors as appropriate.

.

Black

Handle Yellow

Handle

Black

Handle

Black

Handle

Blue

Handle

3G9849b

CH Flow

Filling

Loop

CH

Return

DHW

Inlet

DHW

Outlet2

1

3


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29

INSTALLATION


3G

9705

Safety Valve

Drain Connection

15mm elbow

or fittings

(not supplied)Safety Valve

Drain Pipe

IMPORTANT. The gas service cock is sealed with a non-metallic blue fibre washer, which must not be overheated whenmaking capillary connections. Refer to Frame 1 for details of the position of the gas connection.

For additional gas supply information refer to “Gas Supply” on page 8.

28 GAS CONNECTION

The safety valve connection, located at the bottom right-hand side of the boiler, comprises a 15mm diameter stub pipe.

The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupantsof the premises or damage the electrical components and wiring.

29 SAFETY VALVE DRAIN

A purpose made safety valve drain pipe isprovided with the boiler to allow safedischarge through a wall to the outside ofthe building. This is particularly relevant to‘high rise’ installations butcan be used for allinstallations.

Black

Handle Yellow

Handle

Black

Handle

Black

Handle

Blue

Handle

3G9849c

Gas Pressure

Test Point

Gas

Supply

Black

Handle Yellow

Handle

Black

Handle

Black

Handle

Blue

Handle3G9849d

Safety

Drain

Valve



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30

INSTALLATION


30 FILLING

IMPORTANT - when filling:When filling, there may be a slight water leak from the airvent therefore electrical connections should be protected.

Note. The domestic hot water flow rate isautomatically regulated to a maximumof 12.4 l/m (2.8 gpm).

Black

Handle Yellow

Handle

Black

Handle

Black

Handle

Blue

Handle3G9849d

Safety

Drain

Valve

Black

Handle

Black

Handle Yellow

Handle

Black

Handle

3G9862

Blue

HandlesSafety

Drain

Valve

4. Once pressure gauge dial readsbetween 1 - 1.5 bar turn the fillingloop isolation valves back to theclosed position.

1. Ensure Filling Loop isconnected

2. Ensure dust cap on auto airvent is slackened off (refer toFrame 68).

3. Check all isolation handlesare in the open position

Note that isolation handles are shownin the OPEN position on this picture.

Black

Handle

Black

Handle

Blue

Handle

3G9865

5. Disconnect filling loop at the LH side, ensuringwasher is retained and screw on cap.

Note. Fully open all DHW taps and ensure water is flowingfreely. Once satisfied close all taps.

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INSTALLATION


32 INTERNAL WIRING

The Keston 30C boiler comes pre-fitted with 1.8m ofmains cable. This must be connected to a permanentlive supply and NOT switched by thermostats/programmers. For installers wishing to change thiscable refer to Frame 33.

The Keston 30C boiler comes pre-fitted with a link wirebetween the room thermostat/Timer connections on theterminal strip. This creates a permanent call for heatand must be removed when adding a room thermostat/programmer.

The terminal block cover carries two spare fuses for themain PCB.

To add thermostat/programmer:

1. Isolate the mains supply to the boiler.

2. Remove the front panel. Refer to Frame 44.

3. Swing the control box down into the servicing position.Refer to Frame 50.

4. Route incoming cables through the grommets in bottompanel (note, grommets are ‘blind’ and will requirepuncturing) and secure using clamps and screwsprovided in hardware pack.

5. Pull off rubber terminal block cover.

6. Connect wires to terminal block, as shown below

7. Re-assemble in reverse order.

continued . . . .

31 ELECTRICAL CONNECTIONS

Wiring should be 3 core PVC insulated cable, not less than0.75mm2 (24 x 0.2mm), and to BS 6500 Table 16. For IEreference should be made to the current ETCI rules forelectrical installations.

Connection must be made in a way that allows completeisolation of the electrical supply such as a double pole switchhaving a 3mm (1/8") contact separation in both poles. Themeans of isolation must be accessible to the user afterinstallation.

WARNING. This appliance MUST be earthed.

A mains supply of 230Vac ~ 50 Hz is required.

The fuse rating should be 3A. All external controls andwiring must be suitable for mains voltage.

Wiring external to the boiler MUST be in accordance withthe current I.E.E. (BS.7671) Wiring Regulations and anylocal regulations.

Spare PCB fuses

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32

INSTALLATION


3G

95

60

N

L

N

FROST

STAT

(OPTIONAL)

ROOM

STAT/

TIMER

Room

Stat or

Prog.

Room

Stat

OptionalFrost Stat

DIAGRAM A

Internal Timer or

Programmable Room Stat

3G

95

61

N

L

N

FROST

STAT

(OPTIONAL)

ROOM

STAT/

TIMER

RoomStat

OptionalFrost Stat

DIAGRAM B

External

Timer

Keston offer 2 kits as follows:(see individual kits for installation instructions)

Electronic Timer (7 day) kit - 7 day electronic CH timer fits into the control box of the boiler. This can be fitted in conjunctionwith a room thermostat. Features English language installation help messages.

32 INTERNAL WIRING.... CONT’D

(1) ROOM THERMOSTAT WITH INTERNAL BOILER TIMER OR(2) PROGRAMMABLE ROOM THERMOSTAT

1. Remove link wire between room stat/timer terminals.

2. Connect room stat across terminals as shown in diagram A

3. If room stat has a neutral connection, connect this toterminal N (load) in the fused spur.

3G

97

07

a

L

N

FROST

STAT

(OPTIONAL)

ROOM

STAT/

TIMER

OpenTherm

Harness

Weather

Compensation

OptionalFrost Stat

OutsideSensor

DIAGRAM C

Weather Compensation Kit

Timer

ROOM THERMOSTAT + TIMER

1. Remove link wire between room stat/timer terminals.

2. Connect room stat and programmer in series as shown in diagram B.

3. If room stat has a neutral connection, connect this to terminal N (load) inthe fused spur.

FROST THERMOSTAT

If parts of the system are vulnerable to freezing or the programmer is likely to beleft off during cold weather, a frost stat should be fitted in conjunction with a pipethermostat.

1. Position the frost thermostat in a suitable position, i.e. area vulnerable tofreezing.

2. Connect frost stat across terminals marked frost stat shown in diagramsA & B.

WEATHER COMPENSATION KIT

The two wires from the weather compensation kit (outsidesensor), must be connected into the two right hand terminals asshown in diagram C.

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INSTALLATION


33 REPLACING PRE-FITTED MAINS CABLE

If it is necessary to use an alternative mains cable to the one pre-fitted then use the following guide.

Replacement wiring should comply with notes in Frame 31.



3. Swing the control box down into the service position. Refer toframe 50.

4. Remove the live, neutral and earth wires from the terminal block.

5. Loosen the cable clamp and withdraw the mains cable.

6. Route replacement cable back through the cable clamp andgrommet and re-tighten to provide cord anchorage.

7. Connect the live, neutral and earth wires to the terminal strip.

When making the mains electrical connections to the boiler it isimportant that the wires are prepared in such a way that theearth conductor is longer than the current carrying conductors,such that if the cord anchorage should slip, the current carryingconductors become taut before the earthing conductor.

8. Swing the control box back up into the operating position andre-fit the front panel ensuring a good seal is made.

34 FITTING THE WEATHER COMPENSATION KIT - SUPPLIED AS STANDARD

This kit provides the facility to apply outside air temperature control to the boiler water flow temperature which providesenergy savings. The outside sensor provided measures outside air temperature and sends a signal to the boiler, whichadjusts the maximum boiler flow temperature in response. If outside air temperature is greater than the system designtemperature, the boiler flow temperature is reduced providing running cost savings. The boiler will operate in thecondensing mode more frequently increasing savings.

Once the sensor is fitted it is automatically detected.

The sensor operation may be configured by adjustment of the boiler operating parameters, if necessary.

5

4

Kit Contents

A. Outside Air SensorA

3G10011

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INSTALLATION


35 FITTING THE KITNote. A timer should be fitted to the system so that CH will be switched off when appropriate.

Fitting the sensor

The air sensor should be located on an external wall of the building to be heated. Fix the sensor to a north/north-east facingwall to avoid direct radiation from the sun. The air sensor should be located to avoid any heating effect from the boiler flue.

To fix the air sensor to the wall, unscrew the sensor box plastic cover and screw/plug the sensor body to the wall.

Wire a twin core 0.5mm2 cable from the sensor to the boiler through an RH grommet located on the underside of the boiler.Cable length between sensor and boiler should be no greater than 20m. Note that this connection is safety extra low voltage. Itis not necessary for the person carrying out the wiring to be approved to Part P of the Building Regulations.

Avoid running this cable alongside mains voltage cables.

Wiring the Weather Compensation Kit to the Keston 30C.

1. Isolate the electricity supply to the boiler.

2. Remove the boiler front panel (refer to boiler installation instructions).

3. Hinge down the control box.

4. Connect the sensor wiring into the RHS of the 4 way terminal block and secure with a cable clamp.


4

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INSTALLATION


36 CH OPERATION

The On and Off time control of central heating should be controlled by a separate timer. This can be a standard unit or eitherof the options available from Keston 30C range.

During programmed On times the Central Heating Radiator Flow Temperature is controlled by the boiler relative to theOutside Temperature as shown in the following diagram.

The Room temperature can be adjusted using the Central Heating Temperature Control Knob on the boiler as follows.Essentially rotating the knob clockwise increases the room temperature and rotating the knob anti-clockwise decreases theroom temperature.

If the Central Heating Temperature Control Knob is rotated fully clockwise then for an Outside Temperature of 15°C a FlowTemperature of 40°C will be provided. For an Outside Temperature of 0°C a Flow Temperature of 78°C will be provided withthe relationship varying lineally in between these 2 points (line on the graph 2.5)

If the Central Heating Temperature Control Knob is in its mid position then for an Outside Temperature of 15°C a FlowTemperature of 36°C will be provided. For an Outside Temperature of 0°C a Flow Temperature of 65°C will be provided withthe relationship varying lineally in between these 2 points (line on the graph between 1.6 and 1.8)

If the Central Heating Temperature Control Knob is rotated fully anti-clockwise then for an Outside Temperature of 15°C aFlow Temperature of 30°C will be provided. For an Outside Temperature of 0°C a Flow Temperature of 44°C will be providedwith the relationship varying lineally in between these 2 points (line on the graph 1.0)

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INSTALLATION


37 EXTERNAL ELECTRICAL CONTROLS

Wiring External to the Boiler

The fuse rating should be 3A.

Wiring external to the boiler MUST be in accordance withthe current I.E.E. (BS.7671) Wiring Regulations and anylocal regulations.

Frost Protection

If parts of the pipework run outside the house or if theboiler will be left off for more than a day or so then a frostthermostat should be wired into the system.

This is usually done at the programmer, in which casethe programmer selector switches are set to OFF and allthe other controls MUST be left in the running position.

The frost thermostat should be sited in a cold place butwhere it can sense heat from the system.

Note. If the boiler is installed in a garage it may benecessary to fit a pipe thermostat, preferably on thereturn pipework.

Earths are not shown for clarity but must never beomitted.

OpenTherm Programmable Room Temperature Control

Note. These terminals MUST ONLY be connected to anOpenTherm Controller, (such as the Keston Chronothern RoomController (c.17.4.21.00.0). Connecting any other device /control wiring may destroy the primary PCB.



3. Swing the control box down into the servicing position.Refer to Frame 50.

4. Remove the control box cover. Refer to Frame 62, no’s 3and 4.

5. Unclip the 3 way in-line connector containing 2 purplewires and 2 red wires.

6. Connect this 3 way connector to the 3 way connectorcontaining 2 purple wires wired from the 4 way terminalblock.

7. Connect the two wires from the OpenThermProgrammable Room Temperature Control to the two LHconnections of the terminal block as shown.


5 6

7

3G9990a

L NRoom Stat Frost Stat

Mains In

Programmable Room Stat

L NRoom Stat Frost Stat

Mains In

Use of General Live for Room Stat

ProgrammableRoomStat

RoomStat

OptionalFrost Stat

OptionalFrost Stat

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INSTALLATION


38 WIRING DIAGRAM

1

X1A

X1B

X1C

X1D

X2A

X2B

X3

X7A

X7B

X6

X8

21

23

12

31

23

41

23

41

23

54

12

31

2

X7D

12

12

X7C

12

12

34

56

12

34

56

78

910

11

2055

31-1

0207

Wat

erP

ress

ure

Sen

sor

Wat

erFl

owTu

rbin

e

Fan

Hea

tE

xcha

nger

Ther

mis

tor

Flow

Ther

mis

tor

Ret

urn

Ther

mis

tor

Flam

eS

enso

rE

lect

rode

Spa

rkE

lect

rode

Spa

rkG

ener

ator

PCB

Gas

Valv

eFl

ueTh

erm

osta

t

Pum

p

Cha

ssis

Ear

thIn

tern

alTi

mer

Low

Volta

geC

onne

ctio

n

Inte

rnal

Tim

erH

igh

Volta

geC

onne

ctio

n

Ser

vice

Con

nect

or

Inlin

eco

nnec

tor

Fuse

dat

4AT

Div

erte

rVa

lve

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38

INSTALLATION


WARNING. Whilst effecting the required gas tightness test and purging air from the gas installation,open all windows and doors, extinguish naked lights and DO NOT SMOKE.

A. Electrical Installation

1. Checks to ensure electrical safety should be carried out bya competent person.

2. ALWAYS carry out the preliminary electrical system checks,i.e. earth continuity, polarity, resistance to earth and shortcircuit, using a suitable test meter.

B. Gas Installation

1. The whole of the gas installation, including the meter,should be inspected and tested for tightness and purged inaccordance with the recommendations of BS. 6891.In IE refer to IS.813:2002.

2. Purge air from the gas installation by the approvedmethods only.

39 COMMISSIONING AND TESTING

GENERALPlease Note: The combustion for this appliance hasbeen checked, adjusted and preset at the factory foroperation on the gas type defined on the appliancedata plate. No measurement of the combustion isnecessary. DO NOT adjust the air/gas ratio valve.

Having checked:

- That the boiler has been installed in accordancewith these instructions.

- The integrity of the flue system and the flueseals, as described in the Flue Installationsection.

Proceed to put the boiler into operation as follows:

CHECK THE OPERATIONAL (WORKING) GASINLET PRESSURESet up the boiler to operateat maximum rate by openinghot tap to maximum flow.

With the boiler operating inthe maximum rate conditioncheck that the operational(working) gas pressure atthe inlet gas pressure testpoint complies with therequirements - refer to “GasSupply” on page 8.

Ensure that this inletpressure can be obtainedwith all other gas appliancesin the property working.

Gas Supply

Gas PressureTest Point

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INSTALLATION


40 INITIAL LIGHTING

1. Check that the system has been filled and that the boiler isnot airlocked. Ensure the automatic air vent cap is open.Refer to Frame 30.

Note.It is important the burner is not operated before the system isfully vented of air. If it is necessary to operate the appliancepump to assist venting of the air this must be done with thegas service cock turned off.

2. Refit the boiler front panel. Refer to Frame 44.

3. Check that the drain cock is closed and that the CH andDHW isolating valves (M, L and G) are OPEN.

4. Check that the electrical supply is OFF.

5. Check that the boiler mode control knob (D) is off.

6. Check that the gas service cock (K) is OPEN.

7. Slacken the screw in the inlet pressure test point (J) andconnect a gas pressure gauge via a flexible tube.

8. Switch the electricity supply ON and check all externalcontrols are calling for heat.

CENTRAL HEATING

9. Set the CH temp control (C) to max and turn the modecontrol knob (D) to , ensure the timer/room stat are on.The boiler control will now go through its ignition sequenceuntil the burner is established.

10. If the boiler does not light the following messages will bedisplayed in rotation “Ignition Lockout” - “1 Check othergas appliances” - “2 Reset boiler” - “3 Contactinstaller”. After 5 attempts the boiler will lock out andcarry on displaying the messages. Reset the boiler (referto Frame 40B). The boiler will repeat its ignition sequence.If reset occurs 5 times within 15 minutes then “Too manyresets” will be shown. If power is removed this will bereset.

When the burner is established the BLUE 'Burner On' neon(F) will be illuminated, the LCD will display “CentralHeating” and “Radiator Temp XXoC”.

DOMESTIC HOT WATER

11. With the boiler firing, set the DHW Temp Control knob(B) to maximum and fully open a DHW tap.

The boiler will continue to run and the display (E) willshow “Hot Water” - “Temperature XXoC” - “HighEfficiency”.

12. Ensure that with the boiler operating the dynamic gaspressure is able to obtain maximum output. Refer toTable 2.

IMPORTANTThe gas input to the burner is regulated by the gas valveaccording to the air flow produced by the fan. It is NOTuser-adjustable. Any interference to sealed settings onthe gas valve will adversely affect operation and renderour warranty void.

For additional gas supply information refer to “Gas Supply”on page 8

13. Turn off the DHW tap.

continued. . . . .

Note. The temperature displayed “XXºC” is thatmeasured at that moment, not the set temperature.

Note. The boiler incorporates a fan overrun cyclewhich MUST NOT be prematurely interrupted byisolation of the mains electricity supply.

LegendA. Pre-heat On/offB. DHW temperature controlC. CH temperature controlD. Off/Summer/Winter/Reset ControlE. Boiler StatusF. Burner ‘on’ indicatorG. CH Flow Isolating ValveH. Pressure GaugeJ. Gas Inlet Pressure Test PointK. Gas Service CockL. DHW Inlet ValveM. CH Return Isolating ValveN. DHW Outlet

3G9863

G

H

J

L

N

M

K

A B E F C D

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40

INSTALLATION


THE DISPLAYThe user control has one neon and one display to inform the user about the status. The display will show the status of theboiler. The neon will show the status of the flame. If no flame is detected the neon is off. When the flame is detected the neonwill be lit permanently.

The display scrolls through a maximum of 3 messages under any operational condition as shown below.

Notes: Boiler frost protection - boiler fires if temperature is below 5º C. The temperatures shown below are for illustration purposes only. The measured temperatures will be shown on the boiler.

40 INITIAL LIGHTING . . . . CONT’D

NORMAL OPERATION MESSAGE 1 MESSAGE 2 MESSAGE 3

Mode knob in standby position and no

heat demand

Standby mode For hot water turn mode

knob clockwise

For central heating turn

mode knob clockwise twice

Mode knob in summer position and no

heat demand

Summer mode For central heating turn

mode knob clockwise

Mode knob in winter position and no

heat demand

Winter mode Timer or room stat off

Domestic hot water operation Hot water Temperature 64ºC High efficiency

Central heating operation Radiator Temp 80ºC High efficiency

Pre-heat operation Pre heat

Central heating

Temperature 59ºC High efficiency

Boiler frost protection Boiler frost protection Temperature 5ºC

Pump overrun Pump overrun

Fan post-purge Fan post-purge

High efficiency

Note. High efficiency will not be shown for central heating operation if the central heating flow temperature knob is set to greater than 73ºC.

3G

97

11

DISPLAY FUNCTIONS IN NORMAL OPERATION

NORMAL OPERATION MESSAGE 1 MESSAGE 2 MESSAGE 3

Pre-heat knob moved to off position Pre heat off

Pre-heat knob moved to on position Pre heat on

DHW temperature knob moved 64ºC DHW temp Hot water

temperature 64ºC

CH temperature knob moved 80ºC CH temp Maximum radiator

temperature 80ºC

May not be achieved for

high flow rates in winter

Mode knob moved to standby position Central heating off Hot water off

Mode knob moved to summer position Summer mode

Standby mode

Central heating off Hot water on

Mode knob moved to winter position Winter mode Central heating on

Mode knob moved to reset position Reset

Hot water on

3G

97

12

DISPLAY FUNCTIONS - SETTINGS CHANGED

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41

INSTALLATION


40 INITIAL LIGHTING . . . . CONT’DINSTALLER MODE

Installer Mode is entered as follows:

1. Turn the DHW temperature control knob full anti-clockwise.

2. Turn the CH flow temperature control knob full anti-clockwise.

3. Turn and hold the mode knob in the reset position for more than 5 secs and then turn it to the Winter or Summer position.

The boiler will display “Installer mode”.

If no faults have occurred the boiler will display “No faults”.

If any faults have occurred a list of faults up to a maximum of 10 including the type of fault and how long ago it occurred will beshown in the following format.

MESSAGE 1 MESSAGE 2 MESSAGE 3

LIST OF FAULTS

Fault 1 (latest fault) Low water pressure 2 days ago

Fault 2 No water flow lockout

Fault 3 Overheat lockout 384 days ago

78 days ago

3G

97

13

a

The boiler will then display the current values offlow temperature, return temperature, domestichot water temperature, DHW flow rate and divertervalve position in the following format:

MESSAGE 1

CURRENT VALUES

Flow temp 80ºC

Return temp 60ºC

DHW temp 64ºC

DHW flow rate 8 l/min

Diverter valve DHW position

3G

9714

Note.

If you would like to hold one of the values on the display to watchits behaviour then turn the reset knob to the reset position while itis displayed and hold it there.

Finally the display will operate in one of two modes. If there is afault then more extensive corrective actions will be shown than areusually displayed for the end user. If there is not a fault then theinformation displayed for current operating states will also bemore extensive than is usually displayed for the end-user (pre-purge, ignition and post purge for example).

Installer mode automatically ends after 10 mins or by moving themode knob to the standby position.

40B RESET PROCEDURE

To reset boiler, turn the mode control knob (D) to reset position and immediately turn knob back to required setting. Theboiler will repeat the ignition sequence.

LegendA. Pre-heat On/offB. DHW temperature controlC. CH temperature control

D. Off/Summer/Winter/Reset ControlE. Boiler StatusF. Burner ‘on’ indicator

A B E F C D

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INSTALLATION


41 GENERAL CHECKS

DOMESTIC HOT WATER (DHW) MODE1. Fully open all DHW taps in turn and ensure that water

flows freely and that the mode knob is either in summeror winter position. The boiler will display

“Hot Water” - “Temperature XXoC” - “HighEfficiency”

where the temperature shown is the current DomesticHot Water temperature.

When the burner is lit the light above the display will beon.

2. Close all taps except the furthest one from the boiler andcheck that the boiler is firing at maximum rate.

This is factory set to give a DHW temperature rise ofapproximately 35oC at the flow rate stated on page 6 under“operation”.

3. Reduce the DHW draw-off rate to about 3 l/min (0.7gpm)and check that the boiler modulates to deliver DHW atapproximately 64oC (with the DHW temperature controlknob set to maximum).

4. Close the DHW tap and check that the main burnerextinguishes. The pump should overrun for 60 secondsduring which the boiler will display “Pump overrun”.The fan will then continue to run for a further 3 minutesduring which the boiler will display “Fan Post Purge”after which the boiler will display one of the following“Standby mode” - “Summer mode” - “WinterMode” depending on the position of the mode knob.

Note. On systems in excess of 2 bar inlet pressure a waterpressure governor may be required to prevent water noise.

Make the following checks for correct operation in:

CH & DHW MODE1. Ensure the CH controls are calling for heat and that the

boiler mode knob is in the winter position and the CH flowtemperature control knob is in the maximum position. TheBoiler will display

“Central Heating” - “Radiator Temp XXC”

where the temperature shown is the current flowtemperature.

When the burner is lit the light above the display will be on.

2. Fully open the DHW tap and check that hot water isdelivered. The boiler will display “Hot water” -Temperature XXoC” - High Efficiency”

3. Gas Rate

Check the boiler gas rate when the boiler is at full DHWoutput. Check at the gas meter, with no other appliance inuse. Refer to Tables 2 and 3 for gas rates.

4. Close the DHW tap. The burner should remain on and the boilerwill display “Central heating” - “Radiator temp XXC”.

5. Set the central heating external controls to off. The burnerwill go off and the fan and pump continue to run for 4minutes. The boiler will display “Pump overrun” after whichthe boiler will display one of the following: “Standby mode”- “Summer mode” - “Winter mode” depending on theposition of the mode knob.

6. Check the correct operation of the timer (if fitted) and allother system controls. Operate each control separately andcheck that the main burner responds.

WATER CIRCULATION SYSTEM

1. With the system COLD, check that the initialpressure is correct to the system designrequirements.

For pre-pressurised systems, this should be 1.0bar.

2. With the system HOT, examine all waterconnections for soundness. The system pressurewill increase with temperature rise but should notexceed 2.5 bar.

3. With the system still hot, turn off the gas, water andelectricity supplies to the boiler and drain down tocomplete the flushing process.

Note: A flushing solution should be used during theflushing procedure. Flushing solutions: FernoxSuperfloc, Sentinel X300 (new systems) or X400(existing systems). Refer to Frame 5.

4. Refill and vent the system, add inhibitor (seeFrame 5), clear all air locks and again check forwater soundness.

5. Reset the system initial pressure to the designrequirement.

WATER TEMPERATURES

Temperatures can be selected using the CH and DHW thermostats.

Knob Setting CH Flow Temp DHW Outlet TempoC (oF) oC (oF)

Max 80 (176) 64 (147)

Min 30 (86) 40 (104)

6. Balance the system. Refer to Frame 4.

7. Check the condensate drain for leaks and check that it isdischarging correctly.

8. Finally, set the controls to the User's requirements.

Notes.

1. If the pump has not operated in the last 24 hours it will runbriefly to prevent seizure

2. If the diverter valve has not operated in the last 24 hours itwill be operated briefly to prevent seizure. These twooperations will not occur at the same time.

Note. The temperature displayed “XXºC” is thatmeasured at that moment, not the set temperature.

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INSTALLATION


42 HANDING OVER

7. If a timer is fitted draw attention to the timer UsersInstructions and hand them to the householder.

8. Loss of system water pressure

Explain that the dial underneath the boiler indicates thecentral heating system pressure and that if the normalCOLD pressure of the system is seen to decrease over aperiod of time then a water leak is indicated. Explain the re-pressurising procedure and if unable to re-pressurise or ifthe pressure continues to drop a registered local heatinginstaller should be consulted.

9. Explain boiler reset procedure (refer to Frame 41B).

10. After installation and commissioning please complete the

Commissioning Checklist before

handover to the customer. For IE, its is necessary tocomplete a “Declaration of Conformity” to indicatecompliance to I.S. 813:2002.

IMPORTANT

11. A comprehensive service should be carried out ANNUALLY.

Stress the importance of regular servicing by a Gas SafeRegistered Engineer. In IE servicing work must be carriedout by a Registered Gas Installer (RGII).

12. Inform the householder of the guarantee form and therequirement to register it to receive the full benefit of thewarranty.

1. Make the householder aware that the user instructionsare located in the pocket in the drop down door andexplain his/her responsibilities under the relevantnational regulations.

2. Explain and demonstrate the lighting and shuttingdown procedures.

3. The operation of the boiler and the use and adjustmentof all system controls should be fully explained to thehouseholder, to ensure the greatest possible fueleconomy consistent with the household requirementsof both heating and hot water consumption.

Advise the User of the precautions necessary to preventdamage to the system and to the building, in the eventof the system remaining inoperative during frostyconditions.

4. Explain the function and the use of the boiler heatingand domestic hot water controls.

Explain that due to system variations and seasonaltemperature fluctuations DHW flow rates/temperaturerise will vary, requiring adjustment at the draw off tap. Itis therefore necessary to draw the users attention to thesection in the Users Instructions titled “Control of WaterTemperature” and the following statement:

“Additionally, the temperature can be controlled bythe user via the draw-off tap: the lower the rate thehigher the temperature, and vice versa”.

5. Explain the function of the boiler fault mode.

Emphasise that if a fault is indicated, the boiler shouldbe turned off and a Gas Safe Registered Engineerconsulted. In IE contact a Registered Gas Installer(RGII).

6. Explain and demonstrate the function of time andtemperature controls, radiator valves etc., for theeconomic use of the system.

After completing the installation and commissioning of the system the installer should hand over to the householder bythe following actions:

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44

SERVICING


43 SERVICING SCHEDULE

For the very latest copy of literature for specification & maintenance practices, visit our website www.keston.co.uk, where youwill be able to download the relevant information.

WARNING. Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricitysupply to the appliance before servicing.

Combustion testing must be carried out by a competent person using a combustion analyser conforming to BS7927.

To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervalsand serviced as necessary. The frequency of servicing will depend upon the installation condition and usage but should becarried out at least annually.

It is the law that any service work must be carried out by a Gas Safe Registered Engineer. In IE service work must be carriedout by a Registered Gas Installer (RGII).

INSPECTION1. Light the boiler and carry out a pre-service check, noting any

operational faults.

2. Check the flue terminal (and terminal guard if fitted) isundamaged and clear of any obstruction.

3. Check all water and gas joints for signs of leakage. Remake anysuspect joints ensuring a gas tightness check is carried out ifapplicable and the water system is correctly refilled, vented andre-pressurised.

CLEANING PROCEDURENote. In order to carry out either servicing or replacement of

components the boiler front panel must be removed. Refer toFrame 44.

1. Clean the main burner. Refer to frame 46.

2. Clean the heat exchanger & condensate trap/siphon. Refer toFrames 47 & 48.

3. Check the main injector for blockage or damage. Refer to Frame45.

4. Check that the flue terminal is unobstructed and that the fluesystem is sealed correctly.

ALSO IF THE DHW FLOW RATE IS IN QUESTION :-

5. Check the DHW filter for blockage. Refer to Frame 74.

The cleaning procedures are covered more fully in Frames 45-50and MUST be carried out in sequence.

IMPORTANT.

6. After completing the servicing or exchange of componentsalways test for gas tightness.

7. When work is complete the front panel MUST be correctly refitted,ensuring that a good seal is made.

Do NOT OPERATE the boiler if the front panel is notfitted.8. If, for any reason, the condensate trap/siphon has been removed

ensure the trap is refilled with water beforereassembling.

9. Check the gas consumption.

10. Check combustion by connecting the flue gas analyser to the fluegas sampling point as shown in the diagram and measure CO &CO2.

If the CO/CO2 ratio is greater than 0.004 AND the integrity of thecomplete flue system and combustion circuit seals have beenverified and the inlet gas pressure (and gas rate) have beenverified, then contact Keston.

11. Complete the service section in the Benchmark CommissioningChecklist.

GENERALPlease Note: During routine servicing, and after anymaintenance or change of part of the combustioncircuit, the following must be checked:

- The integrity of the flue system and the flue seals,

- The integrity of the boiler combustion circuit andthe relevant seals

- The operational (working) gas inlet pressure atmaximum rate.

- The gas rate

- The combustion performance.

COMPETENCE TO CARRY OUT THE CHECK OFCOMBUSTION PERFORMANCEPlease Note: BS 6798:2009 Specification forinstallation and maintenance of gas-fired boilers ofrated input not exceeding 70kW net advises that:

- The person carrying out a combustionmeasurement should have been assessed ascompetent in the use of a flue gas analyser andthe interpretation of the results.

- The flue gas analyser used should be onemeeting the requirements of BS7927 or BS-EN50379-3 and be calibrated in accordance withthe analyser manufacturers requirements, and

- Competence can be demonstrated bysatisfactory completion of the CPA1 ACSassessment, which covers the use of electronicportable combustion gas analysers inaccordance with BS7967, Parts 1 to 4.

Flue Sampling Point

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SERVICING


44 BOILER FRONT PANEL REMOVAL / REPLACEMENT

REMOVAL

1. Loosen the two screws retaining the front panel.

2. Pull the two spring clips down to disengage and pullpanel forward and upward and remove.

REPLACEMENT

3. Hook the panel onto the top retaining clips.

4. Push the panel until the 2 bottom spring clips engageensuring the 4 control knobs line up with the holes in thefront panel.

5. Re-tighten the two retaining screws.

45 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING

1. Disconnect the electrical leads from thefan.

2. Undo the gas pipe union connection to theinjector housing.

3. Remove the extended nut on the fanmounting bracket.

4. Lift off fan and venturi assembly.

5. Inspect the injector for blockage ordamage.

6. Inspect fan outlet sealing gasket andreplace if necessary.

view from top of boiler

view from bottom of boiler

12

3

1

2

3

5

Flue samplingpoint for concentricflue only

Injector

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SERVICING


46 BURNER REMOVAL AND CLEANING

1. Ensure the sump is fully drained

2. Undo the two screws and remove the sump cover retaining thelower flue manifold.

3. Lift the manifold to clear the bottom sealing gasket and removemanifold.

4. Remove the 2 burner front fixing screws and loosen the 2 rearextended nuts by at least ten turns.

5. Lift off the burner from the combustion chamber. To facilitate theremoval angle the burner as shown.

IMPORTANTThe burner head is a ceramic plaque construction. Care mustbe taken to ensure that the burner is not placed downupon its face as this may cause damage to theceramic.

6. Brush off any deposits that may be on the ceramic witha SOFT brush.

7. Inspect the sealing gasket around the burner for anysigns of damage. Replace as necessary.

1. Remove the cleaning plug taking care with any residual condense.

2. Pull off the rubber pipe noting the position and flush out any deposits withclean water.

3. Replace the cleaning plug and refill the siphon with water.

4. Replace the rubber pipe connector with the twin wall seal fitted to thecondensate siphon.

47 CLEANING THE CONDENSATE TRAP/SIPHON

2

3

2 2

4

4

5

3G9690

1

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SERVICING


3

48 CLEANING THE HEAT EXCHANGER

Note: Ensure the condensate trap/siphonis fully drained before cleaning. Refer toFrame 61.

1. Remove ignition and flame detectionelectrodes. Refer to Frames 56 & 57.

2. It is advisable to replace the sump coverprior to the water flush process.

3. Thoroughly flush the heat exchanger bypouring water into the top of thecombustion chamber ensuring the fulltop area is covered.

4. Remove the sump cover and cleanloose deposits from the sump.

5. Inspect the ignition and detectionelectrodes. Ensure that they are cleanand in good condition - replace ifnecessary.

6. Re-fit the ignition and flame detectionelectrodes, ensuring that both earthtabs are fitted to ignition electrode.

7. Check that the ignition and detectiongaps are correct. Refer to Frames 56 &57.

1

Ignition Electrode Flame Detection

Reassemble the boiler in the following order:

1. Ensure that the condensate trap/siphon is full of water.

2. Refit the burner ensuring the sealing gasket is correctlypositioned and free from damage (tighten the 4 fixingscrews in the sequence shown below).

3. Refit the fan / venturi assembly ensuring the retaining tabsare correctly positioned and the sealing gasket is correctlypositioned and free from damage.

4. Reconnect the fan electrical leads.

5. Remove the sump cover and refit the lower flue manifoldas shown.

49 REASSEMBLY

5

1

6. Refit the sump cover.

7. Refit the boiler front panel.

IMPORTANT. Ensure that the boiler front panel iscorrectly fitted and that a good seal is made.

8. Swing the control box back into its working position andsecure.

9. Turn on the gas supply at the gas service cock.

10. Reconnect the electrical supply.

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SERVICING


50 REPLACEMENT OF COMPONENTS

GENERAL

When replacing ANY component

1. Isolate the electricity supply.

2. Turn off the gas supply.

3. Remove the boiler front panel. Refer to Frame 44.

4. Release the retaining clip and swing the control box downinto its servicing position.

After replacing ANY component check operation of theboiler, including gas tightness, gas rate and combustiontest.

IMPORTANT.When work is complete, the front panel must be correctlyrefitted - ensuring that a good seal is made.

Notes.1. In order to assist fault finding, the control panel has an

LED diagnostic display. The key to boiler faultconditions is shown in Frame 80.

2. In order to replace components in Frames 66-78 it isnecessary to drain the boiler. Refer to Frame 65.

THE BOILER MUST NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED

51 FAN REPLACEMENT

1. Refer to Frame 50.

2. Disconnect the electrical leads from the fan.


4. Remove the extended nut retaining the fanmounting bracket.

5. Lift and remove the fan and venturi assembly.

6. Remove the screw and twist venturi anti-clockwise to remove venturi assembly, notingthe orientation of the venturi in relation to thefan body.

7. Transfer the venturi assembly to the new fan,replacing the ‘o’ ring if evidence of damage ordeterioration is visible.

8. Fit the new fan / venturi assembly ensuringthe retaining tabs are correctly positioned andthe fan outlet sealing gasket is correctlypositioned and free from damage. Refit theextended nut.

9. Reassemble the boiler in reverse order,taking care not to overtighten the screw on thefan mounting bracket.

10. Check the operation of the boiler. Refer toFrames 40 & 41.

4

6

3

4

8 Retaining Tabs

2

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SERVICING


5

4 4

52 BURNER INJECTOR REPLACEMENT


2. Disconnect the electrical leads from the fan.


4. Loosen the screw retaining the fan mountingbracket.

5. Lift and remove the fan and venturi assembly.

6. Remove the 2 injector housing screws.

7. Withdraw the injector housing.

8. Fit the new injector housing complete withinjector.

9. Reassemble in reverse order, ensuring that thenew gas seal supplied is located correctly inthe injector housing.

10. Check operation of the boiler. Refer to Frames40 & 41.

24

3

6

53 BURNER REPLACEMENT

6

6

7

1. See Frame 46.


3. Disconnect 2 flag terminals from the flue thermostat.

4. Undo the two screws and remove the sump cover.

5. Lift the manifold to clear the bottom sealing gasket andremove manifold.

6. Remove the 2 front fixing screws and loosen the 2 rearextended nuts.

7. Lift off the burner from the combustion chamber. To facilitatethe removal angle the burner as shown.

8. Fit the new burner, replacing any damaged or deterioratingsealing gasket.

9. Reassemble in reverse order. Refer to Frame 49.

10. Check the operation of the boiler. Refer to Frames 40& 41.

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SERVICING


54 CONTROL THERMISTOR & RETURN THERMISTOR RENEWAL


2. Unclip the control thermistor from the flow pipe and withdraw it from theboiler.

3. Unclip the return thermistor from the return pipe and withdraw it from theboiler.

4. Disconnect the electrical leads from the thermistors.

5. Reconnect the electrical leads to the new thermistors and reassemble inreverse order, ensuring that the thermistors are securely fitted to the pipeson the thermistor locator tabs as shown.

6. Check the operation of the boiler. Refer to Frames 40 & 41.

2

3

Thermistor Locator Tab(with thermistor fitted)

5

55 FLUE THERMOSTAT REPLACEMENT

1. Refer to Frame 50.2. Undo the two screws and remove

the sump cover plate.3. Disconnect the two flag terminals

from the flue thermostat.4. Lift the manifold to clear the bottom

sealing gasket and removemanifold. .

5. Unscrew the two M3.5 screws thatconnect the thermostat to themanifold.

6. Replace thermostat with new partand then refit the two screws,remembering to fit rubber gasketand sealing clamp.

Flue Thermostat

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SERVICING


56 IGNITION ELECTRODE REPLACEMENT1. Refer to Frame 50.

2. Remove the burner. Refer to Frame 53.

3. Unplug the ignition lead from the electrode.

4. Remove the earth lead from the ignitionelectrode.

5. Remove the 2 screws holding the ignitionelectrode to the combustion chamber.

6. Remove the electrode.

7. Fit the new ignition electrode, using the newgasket supplied. Check dimensions as shown.

8. Reassemble in reverse order.


Ignition Electrode

3mm

Straight e

dge

Spark Gap

3.5mm

57 FLAME DETECTION ELECTRODE REPLACEMENT

Flame Detection Electrode

12.5mm

Straight e

dge


2. Remove the burner. Refer to Frame 53.

3. Unplug the flame detection lead from theelectrode.

4. Remove the 2 screws retaining the detectionelectrode.

5. Remove the electrode.

6. Fit the new flame detection electrode, usingthe new gasket supplied.



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SERVICING


59 GAS CONTROL VALVE REPLACEMENT


2. Unplug the electrical plug connection from thegas control valve and disconnect the earthwire.

3. Undo the union nut on the outlet of the gascontrol valve.

4. Undo the gas inlet pipe union at the inlet tothe gas control valve.

5. Loosen the back nut retaining the valve to thebracket and withdraw the valve forwards.

6. Fit the new gas control valve ensuring the twosealing washers are in place and reconnectgas and electrical connections.


2

4

5

58 SPARK GENERATOR REPLACEMENT

1. Refer to Frame 50.2. Disconnect the leads from the

spark generator.3. Remove the M5 screws securing

the spark generator to the boilerchassis.

4. Fit the new spark generator and re-assemble in reverse orderensuring the two earth leads arecorrectly replaced.

5. Check operation of the boiler. Referto Frames 40 & 41.

Spark Generator

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2

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SERVICING


60 DIVERTER VALVE ACTUATOR REPLACEMENT


2. Remove the electrical plug.

3. Using a suitable tool pull out the retainingclip and lift the diverter head from thebrass body.

4. Fit new actuator head and reassemble inreverse order.

6. Check operation of the boiler. Refer toFrames 40 & 41. Diverter Valve Actuator

Retaining Clip

3G9690


Note: Ensure condensate trap is fully drained before removal.

2. Pull off the rubber pipe at the sump drain.

3. Disconnect the condensatedrain pipe.

4. Remove the cleaning plug

5. Turn the siphon clockwiseto disengage and lift toremove.

6. Reassemble in reverseorder.

7. When reassemblingensure the trap is full ofwater.

8. Check operation of theboiler. Refer to Frames 40& 41.

61 CONDENSATE TRAP/SIPHON REPLACEMENT

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2

Siphon5

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SERVICING


62 MAIN PCB REPLACEMENT

Note. Fit the earth strap provided with the PCB to your wrist and secure to a suitable earth on the boiler chassis.

3

4

6

5

PlasticClip

5

7

Ribbon Cable Connection

8. Re-connect all plug connections.


10. Turn power back on to the boiler, after a few moments thedisplay will start alternating between “c” and “0”. Turn thereset knob fully clockwise and when the display shows “ - ”turn the knob fully anti-clockwise IMMEDIATELY.

Finally move the knob into the required position (Standby,Summer or Winter).

11. Check operation of the boiler. Refer to Frames 40 & 41.


2. Note the control knob positions.

3. Remove the 2 screws retaining the control box cover.

4. Carefully lift the 4 retaining clips and remove control boxcover.

5. Unplug all lead connections to the PCB including theribbon cable (to facilitate ribbon cable removal, ease sideclips apart and pull upwards), also where applicable,push the small plastic clip with an electrical screwdriver tofacilitate plug removal.

6. Spring out the two side retaining clips and pull the PCBupwards to clear the 4 corner retaining posts.

7. Take the new Primary PCB and attach the appropriateBoiler Chip Card (BCC).

Note. Ensure the correct orientation of BCC by placing“TOP” side up as shown.

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SERVICING


Note. Fit the earth strap provided with the PCBto your wrist and a suitable earth on the boilerchassis.


2. Remove the main PCB, refer to Frame 62.

3. Unclip the PCB and lift to clear the mountingposts.

4. Fit the new PCB ensuring the 4potentiometer spindles line up with thecontrol knobs which must be in a verticalposition.


6. Check operation of the boiler. Refer toFrames 40 & 41.

63 USER CONTROL PCB REPLACEMENT

3

64 DHW FLOW TURBINE SENSOR REPLACEMENT


2. Remove condensate trap/siphon. Referto Frame 61.

3. Lift off the flow turbine sensor plasticretaining clip.

4. Unplug the electrical connection andtransfer to new turbine sensor.



34

Potentiometer spindle

Control Knobs (to be in vertical position)

PCB

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SERVICING



2. Drain the heating system. Refer to Frame65.

3. Unscrew the pressure gauge and discard.

4. Fit new pressure gauge, using suitablejointing compound.

5. Refill the boiler. Refer to Frame 30.


66 PRESSURE GAUGE RENEWAL

65 DRAINING THE BOILER

DOMESTIC HOT WATER CIRCUIT


2. Close all the DHW water isolating valves on the boilerinlet.

3. To drain the domestic hot water circuit: As there is nodirect drain for the domestic hot water circuit, dependingon the location of the boiler, opening the lowest hot watertap may drain this circuit. However it must be noted thatsome residual water will be experienced duringreplacement of components.

4. After replacing any component on the boiler, close tap,close the drain valve and open all system isolating valves(re-pressurise as appropriate by re-connecting the fillingloop, refer to Frame 30) before proceeding to checkoperation of the boiler.

5. Disconnect filling loop. Refer to Frame 30.


3G9692b

CH

Flow

Gas CH

Return

Filling Loop

CH

Circuit

Drain

3G9690

3G9692c

Gas CH

Return

Filling Loop

DHW

Inlet

DHW

Outlet

CENTRAL HEATING CIRCUIT


2. Close all the CH water isolating valves on the boiler inlet.

3. To drain the primary heat exchanger circuit: Open the drainvalve and attach a length of hose to the CH drain point.

4. After replacing any component on the boiler, remove thehose, close the drain valve and open all system isolatingvalves (re-pressurise as appropriate by re-connecting thefilling loop, refer to Frame 30) before proceeding to checkoperation of the boiler.

5. Disconnect filling loop. Refer to Frame 30.


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SERVICING


67 SAFETY RELIEF VALVE RENEWAL


2. Drain the boiler. Refer to Frame 65.

3. Remove the condensate trap/siphon. Refer toFrame 61.

4. Remove expansion vessel. Refer to Frame 78.

5. Disconnect the electrical connection from thereturn thermistor.

6. Disconnect the 22mm pipe connection at therear of the pump outlet.

7. Pull off the clip retaining the pipe to the heatexchanger swing the pipe to clear the pumpand remove pipe.

8. Undo the safety valve union connection.

9. Withdraw the clip securing the safety valve.

10. Lift safety valve from boiler.

11. Fit the new safety valve and reassemble inreverse order ensuring the new ‘o’ ring is fittedto the top of the return pipe.

12. Refill boiler. Refer to Frame 30. Checkoperation of boiler. Refer to Frames 40 & 41.

68 PUMP AUTOMATIC AIR VENT REPLACEMENT


2. Drain the boiler. Refer to frame 65.

3. Remove the expansion vessel. Refer to Frame 78.

4. Firstly, increase access area by disconnecting the22mm pipe connection at top of pump chamber andbottom of heat exchanger and remove pipe Refer toFrame 67 (no’s 5,6 & 7).

5. The automatic air vent head is retained in the pumpbody with a bayonet connection. The air vent headand float assembly is removed by turning the headanti-clockwise (viewed from above) and pullingupwards.

6. Reassembly is the reverse of the above. Ensure theair vent head ‘o’ ring seal is in place when refittingand the new ‘o’ ring is fitted to the return pipe topconnection.

7. Ensure the air vent cap is loose.

8. Refill the boiler. Refer to Frame 30. Check for leaksaround the new air vent joint.

9. Check the operation of the boiler. Refer to Frames 40& 41.

5

6

7

5

8

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SERVICING


70 DIVERTER VALVE INTERNAL CARTRIDGE REPLACEMENT

FRONT CARTRIDGE REPLACEMENT



3. Remove the diverter valve head. Referto Frame 60.

4. Unscrew the top connection to accessthe internal cartridge.

5. Fit the new valve mechanism ensuringthe correct fit of the pin.




4

69 DHW FLOW TURBINE CARTRIDGE REPLACEMENT



3. Remove condensate trap/siphon. Refer toFrame 61.

4. Remove the DHW flow turbine sensor. Refer toFrame 64.

5. Unscrew the top connection to access theinternal part.

6. Fit the new turbine cartridge.

7. Refit the turbine flow sensor




5

REAR CARTRIDGE REPLACEMENT



3. Remove the diverter valve head. Refer to Frame 60.

4. Remove the flow pipe. Refer to Frame 77 no. 12.

5. Disconnect the CH flow pipe and DHW outlet pipe union connectionsunderneath the boiler. Refer to Frame 65.

6. Remove the plate heat exchanger LH fixing screw. Refer to Frame 71.

7. Remove the screw retaining the brass block to the bottom of the boiler casingand lift the brass block clear of the boiler.

8. Unscrew the rear cartridge connection.

9. Fit the new valve mechanism ensuring the correct fit of the pin.




FRONT CARTRIDGE REAR CARTRIDGE

3 49 8

7

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SERVICING




3. Remove condensate trap/siphon. Refer to Frame 61.

4. Remove the diverter valve actuator. Refer to Frame 60.

5. Remove the 2 allen screws securing the plate heatexchanger to the brass housings.

6. Manoeuvre the plate heat exchanger out of the top LH orcentre of the controls area.

71 DHW PLATE HEAT EXCHANGER REPLACEMENT

5

72 PUMP HEAD REPLACEMENT



3. Disconnect the electrical plug from thepump.

4. Remove the 4 Allen screws retainingthe pump head.

5. Remove the pump head.

6. Fit the new pump head.




3

4

7. Fit the new plate heat exchanger, using the new o-ringssupplied.

Note. The mounting pins are offset so the correct positioncan be defined from the location of the holes on the brassmounting.




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SERVICING


74 DHW FILTER CLEANING / REPLACEMENT


2. Isolate the mains cold water supply tothe boiler.

3. Drain the boiler DHW circuit. Refer toframe 65.

4. Remove the DHW flow turbine cartridge.Refer to Frame 69.

5. Unscrew the flow regulator housing.

6. Remove the filter.

7. Clean or replace filter as necessary.



10. Check Operation of the boiler. Refer toFrames 40 & 41.

65

5

73 CH WATER PRESSURE SENSOR REPLACEMENT



3. Remove condensate trap/siphon. Refer toFrame 61.

4. Using a suitable tool pull out the retaining clip.

5. Pull the pressure sensor upwards to remove.

6. Unplug the electrical connection and transferto the new pressure sensor.

7. Push the new pressure sensor onto the rearpump housing and fit retaining clip.



10. Check Operation of the boiler. Refer toFrames 40 & 41.

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SERVICING



2. Drain down the boiler. Refer to Frame 65.

3. Unplug the electrical lead.

4. Unscrew the thermistor (to facilitate removal a13mm socket spanner should be used).

5. Fit the new thermistor using the sealing washerprovided.

6. Reassemble in the reverse order.



76 NO FLOW THERMISTOR REPLACEMENT

4

3

75 DHW FLOW REGULATOR CLEANING / REPLACEMENT


2. Isolate the mains cold water supply to theboiler.

3. Drain the boiler DHW circuit. Refer toFrame 65.

4. Remove the DHW flow turbine cartridge.Refer to Frame 69.

5. Unscrew the flow regulator housing.

6. Inspect the flow regulator for any blockageand remove if necessary.



9. Check Operation of the boiler. Refer toFrames 40 & 41. 6

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SERVICING


14

11

12

10

77 HEAT ENGINE RENEWAL

Refer also to Frames 6 & 7 - ‘Boiler Exploded View’

IMPORTANTBefore starting the removal procedure, protect the gas and electrical controls with a waterproof sheet or plastic bag.

11. Undo the inlet pipe union nut and remove the retaining springclip and remove pipe.

12. Undo the flow pipe union nut and remove pipe.

13. Remove the condensate rubber pipe. Refer to Frame 61, no. 2.

14. Remove the two heat exchanger fixing screws.

15. Remove the Heat exchanger.

16. Reassemble in reverse order, ensuring the heat exchanger LHretaining bracket is correctly positioned. Replace any new ‘o’rings supplied with new heat exchanger and replacing gasketsor seals if any sign of damage is evident. When replacing thespring clips located on both the flow and return pipeconnections, ensure clip is oriented to correctly matchconnecting pipe diameters.

17. Ensure the trap/siphon is filled with water. Refer to Frame 61.





3. Remove the fan / venturi assembly and place on oneside. Refer to frame 51.

4. Remove the burner and place on one side. Refer toFrame 53.

5. Remove the ignition and detection electrodes and diverteractuator head. Refer to Frames 56, 57 and 60.

6. Remove the spark generator. Refer to Frame 58.

7. Remove the gas valve. Refer to Frame 59.

8. Remove the expansion vessel. Refer to Frame 78.

9. Remove the no flow thermistor. Refer to Frame 76.

10. Remove the 2 M5 screws retaining the gas valvemounting bracket and transfer bracket to the new heatexchanger.

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79 BOILER SEALING PANEL SEAL REPLACEMENT

78 EXPANSION VESSEL RECHARGING & REPLACEMENT

RECHARGING


2. Remove the charge point cover.

3. Recharge the tank pressure to 0.75 bar.

4. Re-assemble in reverse order


REPLACEMENT


7. Drain the boiler CH circuit. Refer to Frame 65.

8. Unscrew the union nut on the vessel waterconnection pipe.

9. Support the expansion vessel and unscrew the 2screws from the securing clamp, located on thetop of the boiler, and remove. (Note the positionof the bracket on the vessel)

10. Remove the expansion vessel.

11. Fit the new expansion vessel.




3

9


2. Remove the old seal from the casing andthoroughly clean the casing surfaces.

3. Fit the new seal, ensuring the bottom jointprovides an air tight seal.



Note. Ensure that the boiler front panel iscorrectly sealed, compressing the sealto make an airtight joint.

RechargePoint

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FAULT FINDINGF

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G


80 FAULT FINDING CHART MAIN MENU

Overheat lockout 1 Fill system to 1.0 bar 2 Bleed radiators

3 Check radiator valves open 4 Reset boiler 5 Contact installerGo to Frame 81

Flow Temperature Overheat Lockout

Ignition lockout / Flue Overheat 1 Check other gas appliances work

2 Reset boiler 3 Contact InstallerGo to Frame 82Ignition Lockout

Low water pressure 1 Fill system to 1.0 bar Go to Frame 85Low Water Pressure

No water flow lockout Fill system to 1.0 bar 2 Bleed radiators

2 Bleed radiators

Flame loss 1 Check other gas appliances Go to Frame 86Flame Loss2 contact installer

3 Check radiator valves open 4 Reset boiler 5 Contact installerGo to Frame 83

No Water Flow Lockout

Too many resets Contact installer5 Resets with 15 minutes

Turn power off and on

Fault 8 Contact installer

3 Contact installer

Go to Frame 84False Flame Lockout

Fan fault Contact installer Go to Frame 87Fan Fault

Flow thermistor fault Contact installer Go to Frame 88Flow Thermistor Fault

Return thermistor fault Contact installer Go to Frame 90Return Thermistor Fault

Outside sensor fault Contact installer Go to Frame 90Outside sensor fault

Low mains voltage Contact electricity provider Low mains voltageContact Electricity Provider

PCB Fault Contact installer If PCB is a spare check Boiler Chip Card (BCC) fitted otherwise replace PCB

PCB Replaced Reset boiler Reset the boiler

No water flow thermistor fault Contact installer Go to Frame 89Return Thermistor Fault

Boiler Chip Card Fault Contact installer Go to Frame 92BCC Fault

Go to Frame 93No CH operation but DHW works OKNo CH operation but DHW operates OK

Go to Frame 94No DHW but CH operates OKNo DHW operation but CH operates OK

No Display Go to Frame 95No Display

Note. Boiler status display information is shown in shaded boxes below. Up to six messages will be displayed in rotation.

RESET PROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting.

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65

FAULT FINDING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING


81 OVERHEAT LOCKOUT - 1 FILL SYSTEM TO 1.0 BAR - 2 BLEED RADIATORS -3 CHECK RADIATOR VALVES OPEN - 4 RESET BOILER - 5 CONTACT INSTALLER

Is the Boiler and CH System filled with water andall isolation and radiator valves open?

YES

Fill and vent the system and open allisolation valves, then reset boiler

Is the Flow/Return Differential across the Boiler inexcess of 30°C?

NO

Check that the Pump is rotating freely.Is the Differential now below 20°C?

YES

NO

Check the Flow and Return Thermistors(Refer to Frame 54)

Replace the Pump,then reset boiler

NO

OK, nowreset boiler

YES


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66

FAULT FINDINGF

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G


82 IGNITION LOCKOUT / FLUE OVERHEAT - 1 CHECK OTHER GAS APPLIANCES WORK- 2 RESET BOILER - 3 CONTACT INSTALLER

If the boiler is reset does theboiler ignite for a short time andthen extinguish?

YES

Is the Gas Pressure available atthe Boiler Inlet (>18 mbar)?

Check the detection electrodeand associated harness for:continuity, visual condition andposition (Refer to Frame 57).Check if the condensate pipe isblocked.Replace as necessary

NO Check gas supply andrectify fault

NO

YES

Is approx 215Vdc supply availableat the Gas Valve? (* See note)

YES

Check spark generator andassociated harness for:continuity and visual condition.(Refer to Frame 59) Are thesefunctioning correctly?

YES

Check ignition electrode andassociated harness for:continuity, visual condition andposition. (Refer to Frame 56) Arethese functioning correctly?

Check siphon and condensatedrain pipe work for blockageand rectify if necessary. Boilernow working OK?

Check wiring connectionfrom gas valve to PCB forcontinuity. If the wiring isOK then replace the PCB

NO

Replace SparkGenerator andharness as necessary

NO

Replace IgnitionElectrode andassociated harnessas necessary

NO

Check if burner isdamaged

Unplug gas valve. Is resistancebetween outside pins 4KΩ (±2)?

YES

Replace Gas ValveNO

YES


NO

Check flue for obstruction

NO

Check wiring to thermostat

NO

Check flue temperature alwaysremains below 90ºC

NO

YESClear obstruction

YES Ensure wiring correctlyconnected

YESReplace Thermostat

NO

Replace heat exchanger

* Note: due to the wave form of the rectified voltage, the reading will vary depending on the type of meter used to measurethe value. In general terms a reading greater than 150V indicates that the correct voltage is supplied to the gas valve.

YESReplace burner

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FAULT FINDING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING


83 NO WATER FLOW LOCKOUT - 1 FILL SYSTEM TO 1.0 BAR - 2 BLEED RADIATORS -3 CHECK RADIATOR VALVES OPEN - 4 RESET BOILER - 5 CONTACT INSTALLER

Is the Boiler and CH System filled with water andall isolation and radiator valves open?

YES

Fill and vent the system and open allisolation valves, reset the boiler

Reset the boiler. Is the Flow/Return Differentialacross the Boiler in excess of 30°C?

NO

Check pump connection and check thatthe Pump is rotating freely. Is theDifferential now below 20°C?

YES

NO

Check the Flow and Return Thermistors(Refer to Frame 54)

Check resistance using a suitable multimeterconnected across the thermistor’s terminal pins

At 25 oC expect 9,700 - 10,300 Ohms



Replace the Pump

NO

OK

YES

Check the No Water Flow Thermistor(Refer to Frame 76).

Check resistance using a suitable multimeterconnected across the thermistor’s terminal pins




Does the boiler now work OK?

84 FAULT 8 - CONTACT INSTALLER (FALSE FLAME LOCKOUT)

Reset the boiler, does Boiler Work OK?

NO

Check routing and integrity of internal boilerwiring is OK. Check condition of Flame SenseElectrode and replace if deteriorated.

Separate the flame detection electrode in-lineconnector. Is there continuity between theterminals pins connected to the electrode?

YES

Replace Flame Detection ElectrodeYES

NO

Check routing and integrity of internal boiler wiring.

85 LOW WATER PRESSURE - 1 FILL SYSTEM TO 1.0 BAR - 2 BLEED RADIATORS -3 CONTACT INSTALLER

Are the Boiler and CH System filled with water andall isolation and radiator valves open (checkpressure gauge is between 1 to 1.5 bar)?

NO Fill and vent the system and open all isolationvalves

YES

Are connections on water pressure sensor secure?

NO



YES

Replace water pressure sensor

NORe-fit connections

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FAULT FINDINGF

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G


86 FLAME LOSS - 1 CHECK OTHER GAS APPLIANCES WORK -2 CONTACT INSTALLER

Does the boiler ignite for a shorttime and then extinguish?

YES

Is the Gas Pressure available atthe Boiler Inlet (18 mbar)?

Check the detection electrode andassociated harness for: continuity,visual condition and position(Refer to Frame 57). Check ifcondensate pipe is blocked.Check if flue is blocked.Replace as necessary

NO Check gas supply andrectify fault

NO

YES

Is 215Vdc supply available at theGas Valve while the flame is on?(* See note)

Check spark generator andassociated harness for:continuity and visual condition.(Refer to Frame 58) Are thesefunctioning correctly?

Check ignition electrode andassociated harness for:continuity, visual condition andposition. (Refer to Frame 56) Arethese functioning correctly?

Check siphon and condensatedrain pipe work for blockage andrectify if necessary. Boiler nowworking OK?

Check wiring from gasvalve to PCB for continuity.If the wiring is OK thenreplace the PCB

NO

Replace Spark Generatorand Harness asnecessary.

NO

Replace IgnitionElectrode andassociated harnessas necessary

NO

Replace Gas ValveNO

NO

Check flue for obstruction

NO

Check wiring to thermostat

YESClear obstruction

YES Ensure wiring correctlyconnected

Check if burner isdamaged

Check flue temperature alwaysremains below 90ºC

NO

YESReplace Thermostat

NO

Replace heat exchanger

YESReplace burner

* Note: due to the wave form of the rectified voltage, the reading will vary depending on the type of meter used to measurethe value. In general terms a reading greater than 150V indicates that the correct voltage is supplied to the gas valve.

NO

YES

YES

YES

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FAULT FINDING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING


88 FLOW THERMISTOR FAULT - CONTACT INSTALLER

Remove the Flow Thermistor from the CH FlowPipe and disconnect the wires.

Check the resistance using a suitable multimeterconnected across the thermistor’s terminal pins.




Is the Thermistor value correct?

YES

Is there continuity between the PCB and the Thermistor?

YESReplace PCB

Fit a new ThermistorNO

Check and replace wiring as necessaryNO

89 RETURN THERMISTOR FAULT - CONTACT INSTALLER

Remove the Return Thermistor from the CH ReturnPipe and disconnect the wires.

Check the resistance using a suitable multimeterconnected across the thermistor’s terminal pins.





YES

Is there continuity between the PCB and the Thermistor?


87 FAN FAULT - CONTACT INSTALLER

Does the wiring from the Fan to the PCB havesecure connections at both ends and has notdeteriorated? Does the wiring have continuity?

YES

Rectify Wiring &connections

Is there 230Vac at the Blue and Brown connectionsto the 3 way connection on the Fan?

NO

Replace PCBNO

YES

Replace Fan

YESReplace PCB

Check and replace wiring as necessaryNO

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FAULT FINDINGF

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G


90 OUTSIDE SENSOR FAULT - CONTACT INSTALLER

Disconnect the wires to the outside sensor.

Check the resistance using a suitable multimeterconnected across the Outside Sensor’s terminal

pins.


At 15 oC expect 15,000 - 16,500 Ohms


Is the Outside Sensor value correct?

YES

Is the wiring securely connected between theincoming terminal block boiler connection of theOutside Sensor and the PCB? Replace PCB

Fit a new Outside SensorNO

Securely connect the wiring at theTerminal Block and the PCB

Is the wiring securely connected at both the boilerand Outside Sensor?

YES

NO Securely connect the wiring at both theboiler and Outside Sensor

91 NO WATER FLOW THERMISTOR FAULT - CONTACT INSTALLER

Disconnect the wiring from the No Water Flow Thermistor

Check the resistance using a suitable multimeterconnected across the Thermistor’s terminal pins.





YES

Is the wiring securely connected to the low voltage 11 wayconnector at the front left hand side of the PCB?

YESReplace PCB


Securely connect the wiring to the PCB

Is the wiring securely connected to the No Water FlowThermistor (located in the top of the Heat Exchanger?)

YES

NO Securely connect the wiring to the NoWater Flow Thermistor

NO

NO

YES

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FAULT FINDING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING


92 BOILER CHIP CARD FAULT - CONTACT INSTALLER

Is the correct BCC for the boiler securely inserted into theslot at the front left of the PCB?(identified by the label on the BCC)

YES

NO Securely attach the BCC for the boiler ontothe PCB and after switching power on and‘c0’ being shown, reset the boiler.

Note. Ensure the correct orientation of BCCby placing “TOP” side up.

Replace the BCC with a new BCC (that is correct for theboiler). After switching power on and ‘c0’ being shown,reset the boiler. Is ‘c2’ still shown? Replace PCB

YES

93 NO CH OPERATION BUT DHW WORKS OK

Is the mode knob in the Winter position?

YES

NOMove the mode knob to the Winter position

Are the Timer and the Room Thermostat switchedon?

YES

NOSwitch the Timer and Room Thermostat On

Are the Radiator Valves Open?

YES

NOOpen the Radiator Valves

Is there 230Vac at (A)?

YES

NO There is no Voltage from the Timer/Room Stat.This is not boiler fault. Ensure Voltage issupplied to boiler by rectifying external wiring.

Replace the Diverter Valve

A


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FAULT FINDINGF

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G


94 NO HW BUT CH ON

Does the display show “hot water” -“temperature XXºC” - “high efficiency”?

NO Is the red neonilluminated on theturbine sensor?

YES

Are the flow rates correct as per Frame 2.

Is the wiring between the PCB and thediverter valve motor connected?

YES

YES

Check diverter head fully engaged and clipsecured onto waterset.

YES

Is diverter stuck in the CH position

YES

Check and replace diverter valve motor head.Is Boiler DHW OK?

NO

Change diverter Valve cartridge - rear section

NOAdjust flow rates to achieve 35ºtemp rise and check filter fitted inturbine is not blocked with debris.

NOReconnect wiring orreplace wiring harness ifno continuity.

NO Re-engage diverter headand secure clip towateset

NOReplace PCB

YES Is hot and coldpipework crossed?

Replace PCB

NO

NO

Is the wiring connectedbetween PCB andDHW sensor?

Remove the turbine,and check for debris inthe turbine & filter.Replace turbine ifnecessary. Is DHW OK?

YES

NO

Re-connect wiring

NO

Replace turbine sensor

95 NO DISPLAY

Is there 230Vac to the boiler at L and N?

YES

NO Supply power to the boiler

Is the wiring from the terminal block to the MainPCB connected securely?

YES

NO Connect the wiring from the terminal block to theMain PCB securely.

Is the ribbon cable from the main PCB to the UserInterface PCB connected securely?

NO Connect the ribbon from the main PCB to theUser Interface PCB securely

YES

Replace theUser InterfacePCB

L

N

Is ribbon cable damaged?

YES

Replace ribbon cable

NO

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73

SHORT LIST OF PARTS


When ordering spares please quote:

1. Boiler model

2. Appliance G.C. No.

3. Description.

4. Quantity.

5. Product number.

The following are parts commonly required due to damage orexpendability. Their failure or absence is likely to affect safety orperformance of this appliance.

The list is extracted from the British Gas List of Parts, whichcontains all available spare parts.

The full list is held by British Gas Services, Keston distributorsand merchants.

When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specificationthat we require. Do not use reconditioned or copy parts that have not been clearly authorised by Keston.

Key No. G.C. Part No. Description Qty./boiler Product Number

107 Filling Loop 1 KS301175530

108 Pump Head Kit 1 KS301175670

110 Automatic Air Vent 1 KS301174894

111 Diverter Valve Head 1 KS301174813

112 Diverter Valve Cartridges 1 KS301175668

113 Pressure Relief Valve 1 KS301175413

118 Expansion Vessel 1 KS301175551

121 Plate Heat Exchanger 1 KS301175418

127 Flow Sensor (Hall Effect) 1 KS301175590

128 DHW Flow Turbine 1 KS301175661

131 Water Pressure Sensor 1 KS301175596

135 Pressure Gauge 1 KS301175679

205 Gas Valve kit 1 KS301175562

211 Injector & Housing 1 KS301175611

215 Fan Kit 1 KS301175569

217 Burner 1 KS301175571

229 Siphon Trap Kit 1 KS301175583

232 Turret Manifold Gasket 1 KS301175620

302 Primary PCB 1 KS301175939

302B Boiler Chip Card (BCC) 1 KS301175937

303 CUI Board 1 KS301175713

304 Control Thermistor (Flow/Return) 2 KS301175589

306 Ignition Electrode Kit 1 KS301175591

307 Detection Electrode Kit 1 KS301175592

308 Spark Generator 1 KS301175593

309 Thermistor - No Flow 1 KS301175594

313 Ignition lead 1 KS301175598

320 Detection Lead 1 KS301175604

328 Fuse - PCB 1 KS301175627

403 Heat Engine Gasket Kit 1 KS301175618

504 Front Panel 1 KS301175723

512 Front Panel Door 1 KS301175722

332 Flue Thermostat 1 KS301175949

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SHORT LIST OF PARTS


96 SHORT LIST

30C

107 108 110 111

118

121

127

128

131

135

205211

215 217

229

302

303

304306

307

309 313

320

328

403

504

512

308

232

112

113

3G9977a

302B 332

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INSTALLER NOTIFICATION GUIDELINES

A change to Building Regulations (England and Wales) requires the installer to notify

when installing a heating appliance, as from 1st April 2005.

Competent Person's

SELF CERTIFICATION SCHEME BUILDING CONTROL

Install and commission

this appliance to

manufacturers' instructions

Complete the

Benchmark Checklist

Choose

Buildings Regulations

notification route

Contact your relevant

Local Authority

Building Control (LABC) who

will arrange an inspection

or contact a government

approved inspector

LABC will record the data

and will issue a

certificate of compliance

If you notify via

Gas Safe Register they will

then notify the relevant

Local Authority Building

Control (LABC) scheme

on members behalf

Gas Safe Register Engineers

log on to the engineers section

of the website at

www.gassaferegister.co.uk

or telephone

0800 408 5577

You must ensure that the

notification number issued by

Gas Safe Register is written

onto the Benchmark Checklist

Gas Safe Register will record the

data and will send a certificate

of compliance to the property

IT IS A CONDITION OF THE

MANUFACTURERS WARRANTY

THAT THE BENCHMARK

COMMISSIONING CHECKLIST IS

FULLY COMPLETED AND LEFT

WITH THE APPLIANCE

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THIS PAGE INTENTIONALLY LEFT BLANK

205531-3.pmd 01/07/2010, 10:2677

Gas Safe Register ID N





Gas Safe Register ID Number

205531-3.pmd 01/07/2010, 10:2678

Gas Safe Register ID Number Gas Safe Register ID Number









205531-3.pmd 01/07/2010, 10:2679

June 2010 UIN 205531 A03

Keston pursues a policy of continuing improvement in the designand performance of i ts products.The right is therefore reserved to vary specification without notice.

Keston Boilers, 34 West Common Road, Hayes, Bromley, Kent, BR2 7BX.Telephone: 0208 462 0262 Fax: 0208 462 4459.

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Keston 30C Manual

Documents

Transcript of Keston 30C Manual